A processing method for thin-wall installation plate type elongated blades

Abstract

The present application relates to the technical field of aero-engine blade processing, and particularly relates to a processing method for a thin-wall mounting plate type slender blade, which comprises the following steps: S1, preparing a blank; S2, rough processing of the blade outer contour: a line cutting is used to process the orthographic projection contour shape of the blade, and a surplus is left, so that a rough processing piece composed of a mounting plate and a blade body is obtained, and a blade tip process section is cut at the tip of the blade body during the line cutting; S3, rough processing of the blade body: the blade basin and the blade back of the blade body are rough processed on a vertical numerical control milling machine; S4, fine processing of the bottom surface, the surrounding side surface and the two mounting holes of the mounting plate; S5, clamping on the mounting plate by using a clamp, taking the mounting holes as a positioning reference, clamping the blade tip process section by using a chuck on the machine tool, fine processing of the top surface of the mounting plate, and fine processing of the blade basin, the blade back and the front and rear edges of the blade body; S6, cutting off the blade tip process section by using line cutting, and removing the re-melted layer; S7, polishing the blade body and the mounting plate; and S8, fluorescence detection.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of aero-engine blade processing, in particular to a processing method of a thin-wall mounting plate type slender blade. BACKGROUND

[0002] The rectification blade is assembled in the engine casing through the blade mounting plate, provides a certain direction and flow stability for the compressor or combustion chamber rotor blade, and makes the compressor rotor blade obtain stable working conditions, provides stable high pressure airflow for the combustion chamber, and promotes efficient operation.

[0003] The rectification blade is divided into a shaft neck type blade, a guide window blade and a mounting plate type blade.

[0004] Generally, the mounting plate of the mounting plate type rectification blade is in an arc shape, and is assembled into a whole circle and fixed on the casing during assembly. The main steps of processing this type of blade are: positioning the base material on the alloy block by pouring low melting point alloy to convert the base material reference, processing the mounting plate; drilling the center hole in the blade tip process section, clamping the mounting plate and tightening the center hole, and processing the blade body and the inner side of the mounting plate. The disadvantages are:

[0005] First, the base material reference conversion is completed by pouring low melting point alloy, which involves multiple reference conversions, poor consistency, and the processing quality of the blade body surface is strongly related to the accuracy of the poured alloy. Before batch pouring, 5-8 parts need to be poured for trial processing, which has a large error and batch scrap risk, and low processing efficiency.

[0006] Second, the center hole positioning method is not suitable for thin mounting plates and slender blade bodies. The reason is that the mounting plate is thin (thickness less than 2mm), the clamping area is too small, and the clamping force of the clamp is insufficient. For slender thin-wall blade bodies, when the center hole is tightened, the middle part of the blade body is a typical weak stiffness area, which is prone to obvious surface vibration marks due to the coupling of cutting vibration frequency and inherent vibration frequency of the part. Especially when the blade material is nickel-based high-temperature alloy (such as GH4169, GH4169D, GH3128, etc.), the surface vibration marks of this type of blade body are more obvious. Therefore, a mounting plate type slender thin-wall blade processing method needs to be researched and designed. SUMMARY

[0007] The main purpose of the present application is to provide a processing method of a thin-wall mounting plate type slender blade, which aims to solve the above technical problems.

[0008] In order to achieve the above purpose, the present application provides a processing method of a thin-wall mounting plate type slender blade, which comprises the following steps:

[0009] S1, preparing a blank part: the blank part is a plate-shaped blank obtained after forging;

[0010] S2, rough machining of the blade outer profile: wire cutting is used to process the blade's front projection profile shape, and a margin is left, to obtain a rough machining piece composed of the mounting plate and the blade body, and a blade tip process section is cut at the tip of the blade body during wire cutting;

[0011] S3, rough machining of the blade body: vertical numerical control milling machine is used to rough machine the blade basin and the blade back of the blade body;

[0012] S4, machining of the bottom surface, the surrounding side surface, and the two mounting holes of the mounting plate;

[0013] S5, clamping on the mounting plate by using a clamp, and taking the mounting hole as the positioning reference, and clamping the blade tip process section by using the chuck on the machine tool, machining of the top surface of the mounting plate, and machining of the blade basin, the blade back, and the front and rear edges of the blade body;

[0014] S6, wire cutting to cut off the blade tip process section, and removing the re-melted layer;

[0015] S7, polishing of the blade body and the mounting plate;

[0016] S8, fluorescence detection.

[0017] Preferably, in the step S1, the method for preparing the blank piece comprises the following steps:

[0018] S101, cutting a bar with a diameter of φ64mm and a length of 160mm;

[0019] S102, forging: pre-forging, final forging, and heat treatment are sequentially performed on the bar to obtain a blank piece with a thickness of 28mm±2mm.

[0020] Preferably, in the step S102, before pre-forging, a glass lubricant with a thickness of 0.1-0.2mm is first sprayed on the surface of the bar; then the bar is heated at a temperature of 1120℃±10℃ for 29-50min, and a single forging is performed by using a 30-35MN electric screw press to obtain a pre-forged piece.

[0021] Preferably, in the step S2, when the blade outer profile is rough machined, the bottom surface of the mounting plate, and the front and rear edges of the blade body are all left with a machining margin of 0.5mm.

[0022] Preferably, in the step S3, when the blade body is rough machined, the blade basin and the blade back of the blade body are both left with a machining margin of 0.7mm.

[0023] Preferably, in the step S4, when the mounting plate is machined, the following steps are included:

[0024] S401, a ball end mill with a tool diameter of 16mm and a tool edge radius of 1mm is used to first rough mill the bottom surface and the surrounding side surface of the mounting plate, and then to fine mill the surrounding side surface;

[0025] S402, a ball head with a tool diameter of 10mm and a blade radius of 5mm is used to first rough mill the groove on the bottom surface of the mounting plate, and then to fine mill the bottom surface and the groove of the mounting plate;

[0026] S403, a ball head tool with a tool diameter of 6mm and a blade radius of 0.2mm is used to drill mounting holes;

[0027] S404, a ball head tool with a tool diameter of 12mm and a blade radius of 1mm is used to remove burrs on the bottom surface and the groove plane of the mounting plate, and to remove burrs on the surrounding side surface.

[0028] Preferably, in the step S5, the clamp structure comprises an adapter, a base, a pressing block, and a stop block; the adapter is used to be installed on the rotary table of the double-drive five-axis linkage numerical control machining center; the base is installed on the top end surface of the adapter; a positioning base is installed on the top surface of the base; the pressing block is installed in the vertical mounting groove of the positioning base through a pressing bolt, and the top end of the pressing block is higher than the top surface of the positioning base; the stop block is installed on the top surface of the positioning base; two supporting columns are provided on the top surface of the positioning base, and a vertical positioning pin is inserted in one of the supporting columns; in the step S5, when the clamp clamps the mounting plate, the two supporting columns are supported on the bottom surface of the mounting plate, the positioning pin is inserted in one of the mounting holes of the mounting plate, and one of the long side surfaces of the mounting plate abuts against the vertical side surface of the stop block; the pressing bolt is tightened so that the upper end of the pressing block is pressed against the other long side surface of the mounting plate.

[0029] Preferably, a pressing boss is provided on the pressing block, which is used to press against the long side surface of the mounting plate; a hemispherical block is provided on the side surface of the pressing block near the lower end edge position, which is located directly below the pressing boss, and the hemispherical block abuts against the groove bottom of the mounting groove.

[0030] Preferably, a spring is provided outside the pressing bolt, one end of the spring abuts against the groove bottom of the mounting groove, and the other end abuts against the pressing block.

[0031] Preferably, the step S5 comprises the following sub-steps:

[0032] S501, a ball head tool with a tool diameter of 12mm and a blade radius of 1.5mm is used to sequentially perform rough machining, semi-rough machining, and fine machining on the blade;

[0033] S502, a ball head tool with a tool diameter of 6mm and a blade radius of 3mm is used to perform rough machining on the top surface of the mounting plate, and semi-fine root cleaning on the root of the blade;

[0034] S503, using a ball head tool with a tool diameter of 6mm and a tool edge radius of 2mm, the top surface of the mounting plate is finished, and the root of the blade is cleaned to size.

[0035] Due to the adoption of the above technical scheme, the beneficial effects of the present application are as follows:

[0036] (1) The present application provides a processing method for thin-wall mounting plate type slender blades, which changes the traditional way of converting the reference by pouring low-melting-point alloy for mounting plate type blades, further reduces the risk of batch rejection, shortens the development cycle of mounting plate type blades, and greatly improves the processing efficiency of such blades.

[0037] (2) In the clamp used in the present application, when the compression bolt is tightened for clamping, the upper end of the compression block is pressed on the long side of the mounting plate, forming a surface contact state, which ensures that the clamp changes from a linear contact state to a surface contact state when clamping the blade, so that the originally thin mounting plate has more stable and reliable clamping force, solving the problems of insufficient clamping force of the mounting plate with hole slender thin-wall blade and serious vibration of the milling process, effectively improving the surface vibration of the blade, and greatly reducing the scrap rate of this type of blade during blade processing.

[0038] (3) In the present application, by setting the blade tip process section, when the blade basin and blade back of the blade body are finished, the clamp is clamped on the mounting plate, and the mounting hole is used as the positioning reference, and the chuck on the machine tool clamps the blade tip process section, which plays a good clamping role for the whole blade, overcoming the problem of surface vibration caused by the use of center hole in the prior art. BRIEF DESCRIPTION OF DRAWINGS

[0039] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed in the embodiment or prior art description will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0040] Figure 1 is a structure diagram of a blank;

[0041] Figure 2 is a front view of the blade before the blade tip process section is cut off;

[0042] Figure 3 is a top view of the blade before the blade tip process section is cut off;

[0043] Figure 4 is an exploded view of the structure of the blade and the clamp;

[0044] Figure 5 It is the assembly schematic view of the clamp, the pressing block, the pressing bolt and the spring.

[0045] Figure 6 It is the structure schematic view of the pressing block in the application.

[0046] The figure number explanation: 1, the adapter; 2, the base; 3, the pressing block; 301, the hemispherical block; 302, the pressing boss; 4, the supporting column; 5, the stop block; 6, the positioning pin; 7, the pressing bolt; 8, the positioning base; 8a, the installation groove; 9, the spring; 100, the blank; 201, the installation plate; 202, the blade body; 203, the blade tip process section. DETAILED DESCRIPTION

[0047] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, not all the embodiments. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the application.

[0048] It should be noted that all directionality indications (such as up, down, left, right, front, back, etc.) in the embodiments of the application are only used to explain the relative position relationship, movement condition, etc. between components in a certain posture (as shown in the drawings), and if the certain posture changes, the directionality indications also change accordingly.

[0049] In addition, the description of "first", "second" and the like in the application is only for the purpose of description, and cannot be understood as indicating or implying the relative importance of the indicated technical features or implicitly indicating the number of the indicated technical features. Therefore, the features limited by "first", "second" can explicitly or implicitly include at least one of the features. In addition, the technical solutions of each embodiment can be combined with each other, but it must be based on the realization of those skilled in the art, and when the combination of technical solutions appears contradictory or unachievable, it should be considered that the combination of technical solutions does not exist, and is not within the protection scope required by the application.

[0050] Combination Figures 1 to 6 As shown in the figure, a processing method of a thin-wall installation plate type slender blade, the steps include:

[0051] S1, preparing a blank 100: the blank 100 is a plate-shaped blank obtained after forging.

[0052] S2, rough machining of the blade outer profile: wire cutting is used to process the blade projection profile shape, and a margin is left, to obtain a rough machining piece composed of the mounting plate 201 and the blade body 202. A blade tip process section 203 is cut at the tip of the blade body 202 during wire cutting. The blade tip process section 203 is provided to provide a clamping position for machining the blade body 202.

[0053] S3, rough machining of the blade body 202: vertical numerical control milling machine is used to rough machine the blade basin and the blade back of the blade body 202.

[0054] S4, machining of the bottom surface, the surrounding side surface, and the two mounting holes of the mounting plate 201.

[0055] S5, the mounting plate 201 is clamped by a clamp, and the mounting holes are used as positioning reference, and the blade tip process section 203 is clamped by a chuck on the machine tool, the top surface of the mounting plate 201 is machined, and the blade basin, the blade back, and the front and rear edges of the blade body 202 are machined.

[0056] S6, after the machining of the profile of the blade body 202 and the top surface P of the mounting plate 201 is completed, the blade tip process section 203 is cut by wire cutting, and the re-melted layer is removed. Specifically, the thickness of the re-melted layer after wire cutting is 0.003-0.008mm, that is, the re-melted layer can be completely removed by trimming 0.02-0.03mm of the margin.

[0057] S7, polishing of the blade body and the mounting plate;

[0058] S8, fluorescent detection: the finished blade is accepted by fluorescent penetration inspection, and the qualified blade is finally obtained.

[0059] In the step S1, the method for preparing the blank 100 includes the following steps:

[0060] S101, cutting a bar material with a diameter of φ64mm and a length of 160mm;

[0061] S102, forging: the bar material is sequentially pre-forged, finished forged, and heat treated to obtain the blank 100 with a thickness of 28mm±2mm.

[0062] In this embodiment, in the step S102, before pre-forging, a glass lubricant with a thickness of 0.1-0.2mm is first sprayed on the surface of the bar material; then the bar material is heated at a temperature of 1120℃±10℃ for 29-50min, and a single forging is performed by a 30-35MN electric screw press to obtain a pre-forged piece.

[0063] In this embodiment, in the step S2, when the blade outer profile is rough machined, the bottom surface D of the mounting plate 201 and the front edge E and the rear edge F of the blade body 202 are all left with a machining margin of 0.5mm.

[0064] In the embodiment, in the step S3, when the blade body 202 is roughed, the blade basin and the blade back of the blade body 202 are left with a machining allowance of 0.7mm.

[0065] In the embodiment, the step S4 includes the following steps when the mounting plate 201 is machined.

[0066] S401, a ball end mill with a tool diameter of 16mm and a blade radius of 1mm is used to first rough mill the bottom surface D and the surrounding side surface of the mounting plate 201, and then to fine mill the surrounding side surface;

[0067] S402, a ball end mill with a tool diameter of 10mm and a blade radius of 5mm is used to first rough mill the groove on the bottom surface D of the mounting plate 201, and then to fine mill the bottom surface D and the groove of the mounting plate 201.

[0068] S403, a ball end mill with a tool diameter of 6mm and a blade radius of 0.2mm is used to drill the mounting holes M and N;

[0069] S404, a ball end mill with a tool diameter of 12mm and a blade radius of 1mm is used to remove burrs on the bottom surface D and the groove plane of the mounting plate 201, and to remove burrs on the surrounding side surface.

[0070] In combination with Figure 4 As shown in the step S5, the clamp structure includes an adapter seat 1, a base 2, a pressing block 3, and a stop block 5; the adapter seat 1 is used to be installed on the rotary table of the double-drive five-axis linkage numerical control machining center; the base 2 is installed on the top end surface of the adapter seat 1; a positioning base 8 is installed on the top surface of the base 2; the pressing block 3 is installed in the vertical mounting groove 8a of the positioning base 8 through a pressing bolt 7, and the top end of the pressing block 3 is higher than the top surface of the positioning base 8; the stop block 5 is installed on the top surface of the positioning base 8; two supporting columns 4 are arranged on the top surface of the positioning base 8, and a vertical positioning pin 6 is inserted in one of the supporting columns 4.

[0071] In combination with Figures 2 to 4 As shown in the step S5, when the clamp holds the mounting plate 201, the two supporting columns 4 are supported on the bottom surface D of the mounting plate 201, the positioning pin 6 is inserted in the mounting hole N of the mounting plate 201, and one of the long side surfaces A of the mounting plate 201 abuts against the vertical side surface of the stop block 5; the pressing bolt 7 is tightened so that the upper end of the pressing block 3 is pressed against the other long side surface B of the mounting plate 201. Thus, the mounting plate 201 is clamped and positioned. After clamping, the blade basin and the blade back of the blade body 202 are detected, and the tolerance runout from the blade tip to the blade root is required to be not greater than 0.02mm.

[0072] In combination withFigure 6 As shown, the pressing block 3 is provided with a pressing boss 302 for pressing on the long side of the mounting plate 201, and a hemispherical block 301 is arranged at the position close to the lower end edge of the side of the pressing block 3, which is located directly below the pressing boss 302 and abuts on the groove bottom of the mounting groove 8a. By using the pressing boss 302 and the hemispherical block 301, the pressing block 3 forms a lever structure, and when the pressing bolt 7 is tightened, the hemispherical block 301 serves as a support to make the pressing boss 302 tightly press on the long side B of the mounting plate 201.

[0073] In combination Figure 5 As shown, the pressing bolt 7 is provided with a spring 9, one end of which abuts on the groove bottom of the mounting groove 8a, and the other end abuts on the pressing block 3. The spring 9 is always in a compressed energy storage state. When the pressing bolt 7 is loosened, the pressing block 3 is bounced away under the action of the spring 9, so that the mounting plate 201 can be quickly loosened.

[0074] In the embodiment, the step S5 includes the following sub-steps:

[0075] S501, a ball head cutter with a cutter diameter of 12mm and a cutter edge radius of 1.5mm is used to sequentially perform rough machining, semi-rough machining and finish machining on the blade 202;

[0076] S502, a ball head cutter with a cutter diameter of 6mm and a cutter edge radius of 3mm is used to perform rough machining on the top surface of the mounting plate 201, and semi-finish and root cleaning on the root of the blade 202;

[0077] S503, a ball head cutter with a cutter diameter of 6mm and a cutter edge radius of 2mm is used to perform finish machining on the top surface of the mounting plate 201, and root cleaning to the size on the root of the blade 202.

[0078] After the step S5 is completed, the profile data of the blade 202 is detected by using a three-coordinate.

[0079] The above only describes the preferred embodiments of the present application, and does not limit the patent scope of the present application, and any equivalent structural transformation made under the inventive concept of the present application, or direct / indirect application in other related technical fields is included in the patent protection scope of the present application.

Claims

1. A method of processing an elongated blade of a thin-walled mounting plate type, characterized by the steps of Comprise: S1, preparing a blank (100): the blank (100) is a plate-shaped blank obtained after forging; S2, rough machining of the blade outer contour: the profile shape of the front view of the blade is processed by wire cutting, and a margin is left, to obtain a rough machining part composed of a mounting plate (201) and a blade body (202), and a blade tip process section (203) is cut at the tip of the blade body (202) during wire cutting; S3, rough machining of the blade body (202): rough machining of the blade basin and the blade back of the blade body (202) on a vertical numerical control milling machine; S4, fine machining of the bottom surface, the surrounding side surface, and the two mounting holes of the mounting plate (201); S5, clamping on the mounting plate (201) by using a clamp, taking the mounting holes as the positioning reference, and clamping the blade tip process section (203) by using the chuck on the machine tool, fine machining of the top surface of the mounting plate (201), and fine machining of the blade basin, the blade back, and the front and rear edges of the blade body (202); The clamp structure used comprises an adapter seat (1), a base (2), a pressing block (3), and a stop block (5); the adapter seat (1) is used to be mounted on the rotary table of a double-drive five-axis linkage numerical control machining center; the base (2) is mounted on the top end face of the adapter seat (1); a positioning base (8) is mounted on the top face of the base (2); the pressing block (3) is mounted in the vertical mounting slot (8a) of the positioning base (8) by a pressing bolt (7), and the top end of the pressing block (3) is higher than the top face of the positioning base (8); the stop block (5) is mounted on the top face of the positioning base (8); two supporting columns (4) are arranged on the top face of the positioning base (8), and a vertical positioning pin (6) is inserted in one of the supporting columns (4); When the clamp clamps the mounting plate (201), the two supporting columns (4) are supported on the bottom face of the mounting plate (201), the positioning pin (6) is inserted in one of the mounting holes of the mounting plate (201), and one of the long side faces of the mounting plate (201) abuts against the vertical side face of the stop block (5); the pressing bolt (7) is tightened, so that the upper end of the pressing block (3) is pressed against the other long side face of the mounting plate (201); A pressing boss (302) is arranged on the pressing block (3), and the pressing boss (302) is used to press against the long side face of the mounting plate (201); a hemispherical block (301) is arranged on the side face of the pressing block (3) near the lower end edge position, the hemispherical block (301) is located directly below the pressing boss (302), and the hemispherical block (301) abuts against the slot bottom of the mounting slot (8a); A spring (9) is sleeved on the pressing bolt (7), one end of the spring (9) abuts against the slot bottom of the mounting slot (8a), and the other end abuts against the pressing block (3); By using the pressing boss (302) and the hemispherical block (301), the pressing block (3) forms a lever structure, when the pressing bolt (7) is tightened, the hemispherical block (301) plays a supporting role, so that the pressing boss (302) is tightly pressed against the long side face of the mounting plate (201); S6. Use wire cutting to cut off the blade tip section (203) and remove the remelted layer; S7. Polished blade body and mounting plate; S8. Fluorescence detection.

2. A method of machining thin-walled mounting plate type elongated blades according to claim 1, characterized in that, In step S1, the method for preparing the blank (100) includes the following steps: S101. Cut a bar stock with a diameter of φ64mm and a length of 160mm; S102. Forging: The bar stock is pre-forged, final forged and heat-treated in sequence to obtain a blank (100) with a thickness of 28mm±2mm.

3. A method of machining thin-walled mounting plate type elongated blades according to claim 2, characterized in that, In step S102, before pre-forging, a glass lubricant with a thickness of 0.1 to 0.2 mm is first sprayed onto the surface of the bar stock; then it is heated at 1120℃±10℃ for 29 to 50 minutes, and then forged in one pass by a 30-35MN electric screw press to obtain the pre-forged part.

4. A method of machining thin-walled mounting plate type elongated blades according to claim 1, characterized in that, In step S2, when rough machining the outer contour of the blade, a machining allowance of 0.5 mm is left on the bottom surface of the mounting plate (201) and the front and rear edges of the blade body (202).

5. A method of machining thin-walled mounting plate type elongated blades according to claim 1, characterized in that, In step S3, when rough machining the leaf body (202), a machining allowance of 0.7 mm is left for both the leaf base and the back of the leaf body (202).

6. A method of machining thin-walled mounting plate type elongated blades according to claim 1, characterized in that, In step S4, the processing of the mounting plate (201) includes the following steps: S401. Using a ball end mill with a cutting diameter of 16mm and a cutting edge radius of 1mm, first rough mill the bottom surface and surrounding sides of the mounting plate (201), and then finish mill the surrounding sides. S402. Using a ball end mill with a cutting diameter of 10mm and a cutting radius of 5mm, first rough mill the groove on the bottom surface of the mounting plate (201), and then finish mill the bottom surface and groove of the mounting plate (201). S403. Use a ball end mill with a cutting diameter of 6mm and a cutting edge radius of 0.2mm to drill holes and machine mounting holes; S404. Use a ball end mill with a diameter of 12mm and a cutting radius of 1mm to remove burrs from the bottom surface and groove plane of the mounting plate (201), as well as burrs from the surrounding sides.

7. A method of machining thin-walled mounting plate type elongated blades according to claim 1, characterized in that, Step S5 includes the following sub-steps: S501. Using a ball end mill with a cutting diameter of 12mm and a cutting radius of 1.5mm, the blade body (202) is subjected to roughing, semi-roughing and finishing in sequence; S502. A ball-end cutter with a diameter of 6mm and a cutting radius of 3mm is used to rough machine the top surface of the mounting plate (201) and to semi-finish clean the root of the blade (202). S503. Using a ball-end cutter with a diameter of 6mm and a cutting radius of 2mm, the top surface of the mounting plate (201) is precision machined, and the root of the blade (202) is cleaned to the required size.

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