An electrolytic machining apparatus for the inlet and outlet edges of blades in an integral bladed disk.

Abstract

This invention discloses an electrolytic machining device suitable for the inlet and outlet edges of blades in an integral bladed disk, relating to the field of electrolytic machining technology. The device includes: a machining sleeve containing a machining cavity; a workpiece inlet communicating with the machining cavity at one end of the machining sleeve; an electrolyte inlet on the machining sleeve, which is connected to an electrolyte source via a pipeline; a tool cathode fixed within the machining cavity, with its machining surface facing the workpiece inlet, the shape and size of which are identical to the desired shape and size of the inlet and outlet edges of the blade; and a follower clamping mechanism comprising two follower units, each including a compression spring and a follower auxiliary anode corresponding to the compression spring and partially located at the workpiece inlet; the two follower auxiliary anodes are used to clamp the blades to be electrolytically machined. This device enables electrolytic machining of the inlet and outlet edges of blades in an integral bladed disk, effectively improving the machining quality of the blade inlet and outlet edges.

Description

Technical Field

[0001] This invention relates to the field of electrochemical machining technology, and in particular to an electrochemical machining apparatus suitable for the inlet and outlet edges of blades in an integral bladed disk. Background Technology

[0002] Integral bladed disks (IBs) are a new type of structural component designed to meet the requirements of high-performance aero engines. They integrate the engine rotor blades and the disk into one unit, eliminating the need for tenons, mortises, and locking devices in traditional connections. This reduces structural weight and the number of parts, avoids airflow loss at the tenons, improves aerodynamic efficiency, and greatly simplifies the engine structure. They are now widely used in military and civilian aero engines in various countries.

[0003] Integral bladed disks are mostly made of nickel-based superalloys, a material that is difficult to machine and possesses complex structural features such as spatial twisting, spatial bending, and varying cross-sectional profiles. Furthermore, the inlet and outlet edges of the blades have very small radii of curvature, and their generatrices exhibit a twisted, free-form curve in space, resulting in an extremely complex shape located at the thinnest and weakest points of the blade profile, making them highly susceptible to deformation during machining. Integral bladed disks have stringent precision requirements, allowing no deviations in profile accuracy; they also have strict requirements for surface integrity, demanding the absence of microcracks and stray corrosion.

[0004] Among the many structural features of an integral bladed disk, the inlet and exhaust edges of the blades are the most critical structures affecting the aerodynamic performance of the engine. To reduce aerodynamic losses, the inlet and exhaust edges are thin, complex in structure, and twisted in shape, requiring high profile precision, and are located at the thinnest and weakest ends of the blade body. With the development of the aero-engine field, in order to obtain better power and higher efficiency, and to maximize the power per unit volume, the blade profile is developing towards more curved, twisted, swept, and complex surfaces. The profiles of the inlet and exhaust edges of the blades are becoming increasingly complex, and the precision requirements are becoming increasingly higher, placing higher demands on their precision machining and manufacturing.

[0005] Electrolytic machining, with its processing not being limited by the mechanical properties of materials, no tool cathode wear, no additional residual stress, no recast layer or microcracks, high material removal rate, and processing capabilities and development prospects at the micron and even nanoscale, is gradually becoming the mainstream manufacturing technology for integral bladed disks.

[0006] However, existing electrolytic machining equipment cannot complete the electrolytic machining of the inlet and outlet edges of integral bladed disks. There is no electrolytic machining equipment suitable for the inlet and outlet edges of integral bladed disks, which seriously restricts the machining quality of the inlet and outlet edges of integral bladed disks. Summary of the Invention

[0007] The purpose of this invention is to provide an electrolytic machining apparatus for the inlet and outlet edges of blades of integral bladed disks, so as to solve the problems existing in the prior art and improve the machining quality of the inlet and outlet edges of blades of integral bladed disks.

[0008] To achieve the above objectives, the present invention provides the following solution:

[0009] This invention provides an electrolytic machining apparatus for the inlet and outlet edges of blades in an integral bladed disk, comprising:

[0010] A processing sleeve is provided with a processing cavity inside. One end of the processing sleeve is provided with a workpiece inlet that communicates with the processing cavity. The processing sleeve is also provided with an electrolyte inlet, which is used to connect with an electrolyte source through a pipeline.

[0011] A tool cathode is fixed in the machining cavity, the machining surface of the tool cathode is facing the workpiece inlet, and the shape and size of the machining surface are the same as the shape and size of the blade inlet and outlet edges to be obtained;

[0012] A follower clamping mechanism includes two follower units, each of which includes a compression spring and a follower auxiliary anode corresponding to the compression spring and partially located at the workpiece inlet. The two follower auxiliary anodes are used to clamp the blade to be electrolytically processed. One follower auxiliary anode is tightly fitted to one side of the blade to be electrolytically processed, and the other follower auxiliary anode is tightly fitted to the other side of the blade to be electrolytically processed. The axial direction of the compression spring is the same as the thickness direction of the blade to be electrolytically processed. One end of the compression spring abuts against the inner wall of the processing sleeve, and the other end abuts against the corresponding follower auxiliary anode. The follower auxiliary anode is electrically connected to the blade to be electrolytically processed.

[0013] Preferably, the tool cathode also includes a plurality of auxiliary anodes, all of which are distributed on both sides of the tool cathode and are bonded to the tool cathode with insulating adhesive.

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

[0015] Preferably, the distance between the inlet and outlet edges of the blade requiring electrolytic machining and the machining surface is 0.05mm-0.3mm.

[0016] Preferably, a sliding groove is provided inside the processing sleeve for each of the follower-type auxiliary anodes, the follower-type auxiliary anode is slidably engaged with the corresponding sliding groove, and the compression spring is disposed in the corresponding sliding groove.

[0017] Preferably, the end of the auxiliary anode closest to the processing surface is flush with the processing surface.

[0018] Preferably, the number of auxiliary anodes is two.

[0019] Preferably, the length of the workpiece inlet and the width of the follower-type auxiliary anode are both equal to the length of the inlet and outlet sides of the blade to be electrolytically processed; the blade to be electrolytically processed can fit against the inner wall of the workpiece inlet.

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

[0021] This invention relates to an electrolytic machining device for the inlet and outlet edges of integral bladed disks. This device enables electrolytic machining of the inlet and outlet edges of integral bladed disks. Electrolytic machining is not limited by the mechanical properties of the material, has no wear on the tool cathode, does not generate additional residual stress, is non-contact machining, has no recast layer or microcracks, has a high material removal rate, and ensures the machining shape and consistency of the blade tip, thus effectively improving the machining quality of the inlet and outlet edges of integral bladed disks.

[0022] Furthermore, the auxiliary anode and the follow-up auxiliary anode in this invention can absorb the electric field, improve the machining accuracy of the intake and exhaust sides, and suppress stray corrosion.

[0023] Furthermore, in addition to machining the intake and exhaust edges of integral bladed disk blades, the invention provides an electrolytic machining apparatus suitable for machining the intake and exhaust edges of blades in integral bladed disks, which can also be applied to the electrolytic machining of the intake and exhaust edges of blades in diffusers and other integral equipment. Attached Figure Description

[0024] 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.

[0025] Figure 1 This is a schematic diagram of the electrolytic machining apparatus for the inlet and outlet edges of blades of an integral bladed disk according to the present invention;

[0026] Figure 2 A schematic diagram of the structure for electrolytic machining of the inlet and outlet edges of blades using the electrolytic machining apparatus of the present invention, which is applicable to the inlet and outlet edges of blades of an integral bladed disk.

[0027] Figure 3 This is a partial structural schematic diagram of the electrolytic machining device for the inlet and outlet edges of blades of an integral bladed disk according to the present invention.

[0028] Figure 4This is a schematic diagram of the operation of the electrolytic machining device for the inlet and outlet edges of blades of the present invention, applicable to integral bladed disks;

[0029] Figure 5 This is a schematic diagram of the operation of the electrolytic machining device for the inlet and outlet edges of blades of the present invention, applicable to integral bladed disks;

[0030] In the diagram: 1. Machining sleeve; 2. Connecting block; 3. Follow-up auxiliary anode; 4. Integral bladed disk; 5. Blade; 6. Tool cathode; 7. Auxiliary anode; 8. Compression spring; 9. Machining cavity; 10. Machining gap. 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 inlet and outlet edges of blades of integral bladed disks, so as to solve the problems existing in the prior art and improve the machining quality of the inlet and outlet edges of blades of integral bladed disks.

[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 5 As shown, this embodiment provides an electrolytic machining apparatus suitable for the inlet and outlet edges of blades in an integral bladed disk, comprising:

[0035] The processing sleeve 1 has a processing cavity 9 inside. One end of the processing sleeve 1 is provided with a workpiece inlet that communicates with the processing cavity 9. The processing sleeve 1 is also provided with an electrolyte inlet, which is used to connect with an electrolyte source through a pipeline.

[0036] The tool cathode 6 is fixed in the machining cavity 9. The machining surface of the tool cathode 6 faces the workpiece inlet. The shape and size of the machining surface are the same as the shape and size of the inlet and outlet edges of the blade 5 that need to be obtained.

[0037] The follower clamping mechanism includes two follower units, each of which includes a compression spring 8 and a follower auxiliary anode 3 corresponding to the compression spring 8 and partially located at the workpiece inlet. The two follower auxiliary anodes 3 are used to clamp the blade 5 to be electrolytically processed. One follower auxiliary anode 3 is used to fit tightly against one side of the blade 5 to be electrolytically processed, and the other follower auxiliary anode 3 is used to fit tightly against the other side of the blade 5 to be electrolytically processed. The axial direction of the compression spring 8 is the same as the thickness direction of the blade 5 to be electrolytically processed. One end of the compression spring 8 abuts against the inner wall of the processing sleeve 1, and the other end abuts against the corresponding follower auxiliary anode 3. The follower auxiliary anode 3 is electrically connected to the blade 5 to be electrolytically processed.

[0038] It is worth noting that when both compression springs 8 are in their natural state, the gap between the two follower auxiliary anodes 3 is less than the minimum thickness of the blade 5 that needs to be processed.

[0039] The specific usage method of the electrolytic machining device for the inlet and outlet edges of blades in this embodiment is as follows:

[0040] Taking the electrolytic machining of the inlet edge of blade 5 as an example, firstly, the initial machining position of the inlet edge of blade 5 on the integral bladed disk 4 is determined. This initial machining position needs to ensure that there is a suitable gap between the inlet edge of blade 5 and the tool cathode 6. After determining the initial machining position, the inlet edge of blade 5 to be electrolytically machined is then inserted between the two follower auxiliary anodes 3. The two follower auxiliary anodes 3 are tightly attached to the two side walls of blade 5 under the elastic force of their respective compression springs 8. Then, the integral bladed disk 4 is fixed. Then, electrolyte is injected into the machining chamber 9, and the tool cathode 6 is electrically connected to the negative terminal of the electrolytic power supply. The processed blade 5 is electrically connected to the positive terminal of the electrolytic power supply; and the entire processing sleeve 1 is fixedly connected to the output end of the feed drive device. The function of the feed drive device is to drive the processing sleeve 1 towards the blade 5. The feed drive device can be the feed axis of the machine tool or other drive equipment. Then the electrolytic power supply is turned on. As the electrolytic processing proceeds, the processing sleeve 1 is driven towards the blade 5 by the feed drive device. During the feeding process, the thickness of the part of the blade 5 in contact with the follower auxiliary anode 3 may gradually increase, but under the action of the elastic force of the compression spring 8, the two follower auxiliary anodes 3 can always be in close contact with both sides of the blade 5 (refer to...). Figure 4 and Figure 5 As the feed proceeds, the intake edge of blade 5 is gradually electrolytically processed until the electrolytic processing of the intake edge of blade 5 is completed. Then the electrolytic power supply is turned off, and the processing sleeve 1 is retracted from blade 5 by the feed drive device. Thus, the electrolytic processing of the intake edge of blade 5 is completed.

[0041] In a preferred embodiment, the alternative solution includes two auxiliary anodes 7, distributed on both sides of the tool cathode 6. The auxiliary anodes 7 are bonded to the tool cathode 6 with insulating adhesive, ensuring insulation between them. In this embodiment, a wiring block 2 is also fixed outside the processing sleeve 1. The auxiliary anodes 7 are fixedly connected to the wiring block 2, which is used to electrically connect to the positive electrode of the electrolytic power supply via a wire, thus connecting the auxiliary anodes 7 to the positive electrode of the electrolytic power supply. This connection between the auxiliary anodes 7 and the positive electrode of the electrolytic power supply during processing improves the processing quality of the inlet and outlet edges of the blade 5.

[0042] Specifically, the auxiliary anode 7 is installed around the tool electrode but does not contact it; the follow-up auxiliary anode 3 is always close to the blade body, but the auxiliary anode 7 and the follow-up auxiliary anode 3 have the same function: they can absorb the electric field, suppress the influence of stray corrosion on the blade 5, and improve machining accuracy and surface quality. The specific reasons are as follows:

[0043] Because an external power supply voltage is applied to the two electrodes, a corresponding current flows through the electrolyte between the electrodes, thus forming a current field in the electrolyte. The spatial distribution of this current field directly affects the speed and shape of the electrolytic machining process. When machining the inlet and outlet edges of blade 5, if the follow-up auxiliary anode 3 and auxiliary anode 7 are not provided, the electric field lines will be widely distributed, and the tool cathode 6 will affect the non-machined areas of blade 5, resulting in poor surface quality in these areas. Simultaneously, the strong electric field in the machining area not only prevents the cathode shape from being copied onto the leading and trailing edges but also worsens the surface quality of the inlet and outlet edges due to excessive electric field concentration. In this embodiment, the auxiliary anode 7 and follow-up auxiliary anode 3 absorb the widely distributed electric field, preventing the tool cathode 6 from affecting the non-machined areas of blade 5, while also weakening the electric field in the machining area, thereby improving the surface machining quality of the inlet and outlet edges.

[0044] In the optional schemes of this embodiment, a more preferred approach is to specify the distance between the inlet and outlet edges of the blade 5 requiring electrolytic machining and the machining surface (i.e., Figure 4 and Figure 5 The machining clearance 10 shown is 0.05mm-0.3mm.

[0045] In the optional scheme of this embodiment, it is more preferred that each follower auxiliary anode 3 is provided with a sliding groove in the processing sleeve 1, the follower auxiliary anode 3 slides with the corresponding sliding groove, and the compression spring 8 is provided in the corresponding sliding groove.

[0046] In the optional embodiments of this example, it is more preferred that the end of the auxiliary anode 7 closest to the processing surface is flush with the processing surface.

[0047] In the optional scheme of this embodiment, it is more preferred that the length of the workpiece inlet and the width of the follower auxiliary anode 3 are equal to the length of the inlet and outlet sides of the blade 5 that needs to be electrolytically processed; the blade 5 that needs to be electrolytically processed can fit against the inner wall of the workpiece inlet.

[0048] 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 suitable for the inlet and outlet edges of blades in an integral bladed disk, characterized in that, include: A processing sleeve is provided inside the processing sleeve. One end of the processing sleeve is provided with a workpiece inlet that communicates with the processing cavity. The processing sleeve is also provided with an electrolyte inlet, which is used to connect with an electrolyte source through a pipeline. A tool cathode is fixed in the machining cavity, the machining surface of the tool cathode is facing the workpiece inlet, and the shape and size of the machining surface are the same as the shape and size of the inlet and outlet edges of the blade to be obtained; A follower clamping mechanism includes two follower units, each of which includes a compression spring and a follower auxiliary anode corresponding to the compression spring and partially located at the workpiece inlet. The two follower auxiliary anodes are used to clamp the blade to be electrolytically processed. One follower auxiliary anode is tightly fitted to one side of the blade to be electrolytically processed, and the other follower auxiliary anode is tightly fitted to the other side of the blade to be electrolytically processed. The axial direction of the compression spring is the same as the thickness direction of the blade to be electrolytically processed. One end of the compression spring abuts against the inner wall of the processing sleeve, and the other end abuts against the corresponding follower auxiliary anode. The follower auxiliary anode is electrically connected to the blade to be electrolytically processed.

2. The electrolytic machining apparatus for the inlet and outlet edges of blades of an integral bladed disk according to claim 1, characterized in that: It also includes several auxiliary anodes, all of which are distributed on both sides of the tool cathode and are bonded to the tool cathode with insulating adhesive.

3. The electrolytic machining apparatus for the inlet and outlet edges of blades of an integral bladed disk according to claim 2, characterized in that: The tool cathode is used to be electrically connected to the negative electrode of the electrolytic power supply, and the auxiliary anode and the blade to be electrolytically processed are used to be electrically connected to the positive electrode of the electrolytic power supply.

4. The electrolytic machining apparatus for the inlet and outlet edges of blades of an integral bladed disk according to claim 1, characterized in that: The distance between the inlet and outlet edges of the blade requiring electrolytic machining and the machining surface is 0.05mm-0.3mm.

5. The electrolytic machining apparatus for the inlet and outlet edges of blades of an integral bladed disk according to claim 1, characterized in that: Each of the following auxiliary anodes is provided with a sliding groove inside the processing sleeve. The following auxiliary anode slides in conjunction with the corresponding sliding groove, and the compression spring is provided in the corresponding sliding groove.

6. The electrolytic machining apparatus for the inlet and outlet edges of blades of an integral bladed disk according to claim 2, characterized in that: The auxiliary anode is flush with the processing surface at one end near the processing surface.

7. The electrolytic machining apparatus for the inlet and outlet edges of blades of an integral bladed disk according to claim 2, characterized in that: The number of auxiliary anodes is two.

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