An integrated broaching and grinding tool system and process

Abstract

The present invention discloses an integrated broaching and grinding tool system and process, relating to the field of mechanical processing. The system comprises a broaching machine assembly and a turbine disc clamping device. The broaching machine assembly comprises a broaching machine base, a clamping platform provided within the broaching machine base, a broaching and grinding tool mounted on the clamping platform, and a tractor mechanism connected thereto. Multiple position sensors are mounted on one side of the broaching machine base for obtaining information about the clamping platform's position. The broaching and grinding tool comprises an integrally connected broaching portion and a grinding portion. The turbine disc clamping device comprises a turbine disc drive mechanism for mounting a turbine disc, and a lifter is provided between the turbine disc drive mechanism and the broaching machine base. The present invention integrates the functions of a cutting blade and a grinding wheel, thereby not only improving machining efficiency but also significantly improving machining quality and reducing machining errors of workpieces.

Description

Technical Field

[0001] The present invention relates to the field of mechanical processing, and in particular to a broaching and grinding integrated tool system and process. Background Art

[0002] In traditional machining processes, broaching and grinding are usually separate processes. Broaching is used to remove most of the material, while grinding is used for fine machining to improve the surface quality of the workpiece. However, this separate machining method faces problems such as low efficiency and complex processes during the machining process. Especially in the machining of complex shapes, switching between processes often requires a lot of time and effort. Traditional cutting tools and grinding tools have their own advantages and disadvantages in different application scenarios. Cutting tools are usually used in the rough machining stage where more material is removed. Their advantage is high machining efficiency, but the surface quality of the workpiece is poor; while grinding tools are suitable for fine machining and can significantly improve the surface finish of the workpiece, but the efficiency is low. Therefore, for complex structural parts, combined machining methods have become a process optimization method. For example, for turbine disc mortise and tenon machining, special machining and broaching or grinding, milling and grinding, broaching and milling and other different combination methods can usually be used. However, the combined machining method has problems of complex process and low efficiency, for example:

[0003] CN116833498A discloses a combined electrochemical milling and electrochemical grinding method for the mortise and tenon of an aircraft engine turbine disk. The method comprises the following steps: Step 1: Arrange a forming grinding wheel, a tool cathode, and an electrolyte nozzle in sequence along the machining direction, with the forming grinding wheel and tool cathode connected to the positive and negative poles of a power supply, respectively; Step 2: Move the tool cathode in the machining direction while the electrolyte nozzle supplies electrolyte, achieving large excess removal through electrochemical machining to complete the rough machining of the mortise and tenon; Step 3: After machining the tool cathode, move the forming grinding wheel in the machining direction and perform grinding with the electrolyte supplied by the electrolyte nozzle to achieve small excess removal and complete the fine machining of the mortise and tenon; Step 4: Rotate the turbine disk and repeat Steps 2 and 3 to machine the next groove. This method combines electrochemical milling and electrochemical grinding, resulting in high machining accuracy, but low machining efficiency and strict machining conditions.

[0004] CN114918482A discloses a method for machining wide tenons on turbine disks. The specific steps are as follows: machining a tenon on a test piece made of the same material as the turbine disk, first machining the tenon with slow-moving wire cutting, leaving an allowance on one side, then using high-speed fine broaching to reach the final size, checking whether the tenon size and technical conditions of the test piece meet the design requirements of a single tenon, verifying the correctness of machining a tenon with a slow-moving wire cutting program and whether the fine broaching tool is qualified; machining two symmetrical grooves on a large test piece, first machining the tenon with slow-moving wire cutting, leaving an allowance on one side, then using high-speed fine broaching to reach the final size, checking the correctness of the distance from the tenon working surface of the large test piece to the center of the turbine disk and the inclination angle; when the test piece machined in step 1 and the large test piece machined in step 2 are qualified, formally machining the turbine disk. During the formal machining, the tenon is also machined with slow-moving wire cutting, leaving an allowance on one side, then using high-speed fine broaching to reach the final size, and all the tenons are machined to the final size; and machining the annular groove at the tenon notch. This method combines the processing methods of wire cutting and broaching to process the mortise and tenon, but its processing efficiency is not high and the processing method needs to be changed during the processing.

[0005] CN116728089A discloses a turbine disc mortise and tenon laser cutting-broaching composite processing method and apparatus, comprising a frame, a workbench mounted on the frame, a laser cutting module, a broaching module, a thermal imager, and a cooling device; the workbench is used to secure the turbine disc blank and drive the disc blank to rotate about its axis; the laser cutting module is used to perform preliminary processing and cutting on the disc blank; the broaching module is used to further cut the disc blank after processing by the laser cutting module; the thermal imager is used to collect the temperature of the disc blank; and the cooling device is used to cool the disc blank after laser cutting. This method combines the processing methods of laser cutting and broaching, but the use of laser cutting can easily cause heat accumulation and surface burns, making it difficult to ensure processing accuracy.

[0006] In summary, the current processing of turbine disc tenon and groove mainly has the following problems: 1. The current batch processing method of turbine disc tenon and groove generally adopts broaching. Although broaching is efficient, the integrity of the processed surface is unsatisfactory; 2. The broaching tools, especially the fine broaches, have complex shapes, high manufacturing precision requirements, high costs, and poor surface retention during the broaching process, resulting in poor tenon and groove shape and position accuracy and poor yield; 3. Since the combined processing method requires the use of different processing procedures, it has problems such as poor repeatability, low efficiency, and difficulty in ensuring processing accuracy. Summary of the Invention

[0007] In view of the shortcomings of the existing technology, the purpose of the present invention is to provide an integrated broaching and grinding tool system and process, which integrates the functions of the cutting blade and the grinding wheel, and adopts hydraulic drive to ensure the broaching force and grinding speed; it can not only improve the processing efficiency, but also significantly improve the processing quality and reduce the processing error of the workpiece.

[0008] In order to achieve the above object, the present invention is implemented through the following technical solutions:

[0009] In a first aspect, an embodiment of the present invention provides an integrated broaching and grinding tool system, comprising:

[0010] The broaching machine assembly includes a broaching machine base, a clamping platform provided in the broaching machine base, a broaching and sharpening tool mounted on the clamping platform, and the clamping platform connected to a tractor mechanism; a plurality of position sensors are installed on one side of the broaching machine base, and the position sensors are used to obtain position information of the clamping platform; the broaching and sharpening tool includes a broaching tool portion and a sharpening tool portion connected as one body;

[0011] The turbine disc clamping device comprises a turbine disc driving mechanism for installing the turbine disc, and a lifter is provided between the turbine disc driving mechanism and a broaching machine base.

[0012] As a further implementation, the push-pull mechanism includes a hydraulic cylinder, the clamping platform is connected to the hydraulic cylinder, and the hydraulic cylinder is connected to a hydraulic drive system;

[0013] A positioning shaft is installed in the base of the broaching machine, and the clamping platform is slidably matched with the positioning shaft.

[0014] As a further implementation method, a transition zone is provided between the broaching part and the grinding part, and the transition zone includes a first section and a second section arranged in sequence, wherein the first section is used to connect the broaching part, and the second section is used to connect the grinding part, and has the same shape as the grinding part.

[0015] As a further implementation method, the broaching part is divided into a rough grooving part and a semi-finishing contour grooving part; the rough grooving part is used to broach a triangular groove, and the semi-finishing contour grooving part is used to broach the triangular groove into a turbine disc tenon groove, a gear groove or a sprocket groove.

[0016] As a further implementation, the sharpening part includes a tool base and abrasive particles distributed on the surface of the tool base; the abrasive particles are arranged in a disordered manner or in an ordered manner.

[0017] As a further implementation, the grinding part is provided with a chip groove, and the chip groove is a straight chip groove, an oblique chip groove, a triangular chip groove or a triangular chip groove that alternates positively and negatively.

[0018] As a further implementation, the lifter is connected to a hydraulic cooling and lifting system, and both the hydraulic cooling and lifting system and the hydraulic drive system are connected to a control system.

[0019] As a further implementation method, a broaching position sensor, a grinding position sensor, and a stop position sensor are installed on one side of the broaching machine base; the control system is used to control the hydraulic drive system to stop working according to the detection signal of the stop position sensor, control and adjust the broaching machine speed to the grinding speed according to the detection signal of the grinding position sensor, and control and adjust the broaching machine speed to the broaching speed according to the detection signal of the broaching position sensor.

[0020] In the second aspect, an embodiment of the present invention also provides a processing technology for a broaching and grinding integrated tool system, including: installing the turbine disc to be ground on a turbine disc clamping device, and installing a broaching and grinding tool; performing integrated broaching and grinding processing of the turbine disc tenon and groove according to broaching and grinding parameters, wherein each groove is first broached and then ground.

[0021] As a further implementation, when the grinding position sensor receives a signal, the grinding process is started; when the stop position sensor receives a signal, the lifter is started; and when the broaching position sensor receives a signal, the tool retraction is stopped.

[0022] The beneficial effects of the present invention are as follows:

[0023] 1) This invention solves the problem of requiring a change in machining methods during the integrated machining of turbine disc mortises, keyways, gear slots, and other components. From rough forming to fine machining and polishing, a single device can be used to complete the entire process, eliminating the need for a change in machining methods. This device offers strong adaptability, high machining efficiency, excellent machining precision, and superior surface quality. It can meet the needs of integrated machining of workpieces with varying machining shapes (such as turbine disc mortises, keyways, and gear slots).

[0024] 2) The present invention adopts different abrasive arrangement methods. The array arrangement and staggered arrangement imitate the usual grinding wheel grinding method, while the coarse and fine segmented arrangement of the abrasive solves the problem of single abrasive and fixed processing accuracy of traditional grinding wheels. The whole process from semi-finishing to fine grinding can be completed in one go, and the processing accuracy can be guaranteed.

[0025] 3) Compared with traditional grinding wheels, this invention adopts a chip removal groove structure, which solves the problem of grinding wheel clogging caused by accumulated grinding chips and ensures smooth discharge of grinding chips. It improves processing quality, avoids excessive wear of abrasive particles, and improves grinding transition.

[0026] 4) The present invention has a simple structure, is easy to assemble and operate, avoids excessive modification of the broaching machine, can be easily linked with the traditional broaching machine, reduces the complexity of program editing, saves a lot of processing costs, and significantly improves the economy of integrated forming processing of various types of workpieces. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The accompanying drawings, which constitute a part of the present invention, are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute improper limitations on the present invention.

[0028] Figure 1 is an axonometric view of the overall structure of one or more embodiments of the present invention;

[0029] Figure 2 is an axonometric view of a broaching machine assembly according to one or more embodiments of the present invention;

[0030] Figure 3 is an exploded view of a clamping table according to one or more embodiments of the present invention;

[0031] Figure 4 1 is a three-view diagram of a broaching machine assembly according to one or more embodiments of the present invention, wherein (a) is a front view of the broaching machine assembly, (b) is a side view of the broaching machine assembly, and (c) is a top view of the broaching machine assembly;

[0032] Figure 5 is an exploded view of a turbine disk clamping device according to one or more embodiments of the present invention;

[0033] Figure 6 is an axonometric view of a hydraulic drive system according to one or more embodiments of the present invention;

[0034] Figure 7 is an axonometric view of a control system according to one or more embodiments of the present invention;

[0035] Figure 8 is an axonometric view of a hydraulic cooling lift system according to one or more embodiments of the present invention;

[0036] Figure 9 is an axonometric view of a lifter according to one or more embodiments of the present invention;

[0037] Figure 10 is an isometric view of a grinding tool according to one or more embodiments of the present invention;

[0038] Figure 11 Schematic diagram of finishing after overall removal of excess during the grinding process of a broach according to one or more embodiments of the present invention;

[0039] Figure 12 It is a schematic diagram of discontinuous removal and dressing of the grinding process of a broach according to one or more embodiments of the present invention;

[0040] Figure 13 is a schematic diagram of a longitudinal tree-shaped mortise and tenon groove of a grinding tool according to one or more embodiments of the present invention;

[0041] Figure 14 is a schematic diagram of a grinding tool gear groove according to one or more embodiments of the present invention;

[0042] Figure 15 is a schematic diagram of a keyway of a grinding tool according to one or more embodiments of the present invention;

[0043] Figure 16 is a front view of an arrangement of an abrasive grain array for a broach according to one or more embodiments of the present invention;

[0044] Figure 17 is a front view of a staggered arrangement of abrasive grains for a broach according to one or more embodiments of the present invention;

[0045] Figure 18 is a front view of a coarse and fine segmented abrasive grain of a broach according to one or more embodiments of the present invention;

[0046] Figure 19 is a front view of a straight chip flute of a broaching tool according to one or more embodiments of the present invention;

[0047] Figure 20 is a front view of the oblique chip groove of the broaching tool according to one or more embodiments of the present invention;

[0048] Figure 21 is a front view of a triangular chip flute of a broaching tool according to one or more embodiments of the present invention;

[0049] Figure 22 is a front view of a broach with alternating positive and negative triangular chip flutes according to one or more embodiments of the present invention;

[0050] Figure 23 is a hydraulic circuit diagram of a hydraulic drive system according to one or more embodiments of the present invention.

[0051] Among them, Ⅰ, broaching machine assembly, Ⅱ, turbine disc clamping device, Ⅲ, hydraulic drive system, Ⅳ, control system, Ⅴ, hydraulic cooling and lifting system, Ⅵ, broaching and grinding tool;

[0052] Ⅰ-1, broaching machine base, Ⅰ-2, positioning axis, Ⅰ-3, clamping table, Ⅰ-4, hydraulic spindle, Ⅰ-5, cylinder block, Ⅰ-6, bracket, Ⅰ-7, positioning screw, Ⅰ-8, chip tray, Ⅰ-9, oil storage tank, Ⅰ-10, oil storage tank cover, Ⅰ-11, baffle; Ⅱ-1, guide, Ⅱ-2, fixed table, Ⅱ-3, first drive motor, Ⅱ-4, turbine disc, Ⅱ-5, connecting sleeve, Ⅱ-6, flange, Ⅱ-7 - teaching pendant; Ⅲ-1, oil inlet pipe, Ⅲ-2, second drive motor, Ⅲ -3, oil tank, III-4, three-position four-way solenoid reversing valve, III-5, oil return pipe; IV-1, electrical box, IV-2, control switch, IV-3, stop position sensor, IV-4, grinding position sensor, IV-5, broaching position sensor, IV-6, wire; V-1, lifter, V-2, hydraulic cooling box, V-3, main oil pipe, V-4, auxiliary oil pipe, V-5, cooling pipe, V-6, third drive motor; VI-1, broaching part, VI-2, grinding part, VI-3, transition zone. DETAILED DESCRIPTION

[0053] It should be noted that the following detailed description is illustrative and is intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used in the present invention have the same meaning as commonly understood by those skilled in the art to which the present invention belongs.

[0054] Example 1:

[0055] This embodiment provides a broaching and grinding integrated tool system, such as Figure 1 As shown, it includes a broaching machine assembly I, a turbine disc clamping device II, a broaching tool VI, a hydraulic drive system III, a control system IV and a hydraulic cooling and lifting system V. The turbine disc clamping device II and the broaching tool VI are installed on the broaching machine assembly I, the broaching machine assembly I is connected to the hydraulic drive system III, and the hydraulic drive system III is connected to the control system IV and the hydraulic cooling and lifting system V.

[0056] like Figure 2 and Figure 4 As shown, the broaching machine assembly I includes a broaching machine base I-1, a bracket I-6, a pulling mechanism, a clamping table I-3, a positioning shaft I-2, and a chip tray I-8. The broaching machine base I-1 is mounted on the upper side of the bracket I-6, and the bracket I-6 and the broaching machine base I-1 are embedded in each other to ensure the stability of the connection. The chip tray I-8 is connected to one end of the broaching machine base I-1. In this embodiment, the broaching machine base I-1 is a box-shaped structure with an opening at one end, allowing grinding chips to enter the chip tray I-8 through the opening.

[0057] The tractor mechanism is housed within the broaching machine base (I-1). It comprises a clamping table (I-3), a hydraulic cylinder, and positioning shafts (I-2). Two positioning shafts (I-2) are mounted along the length of the broaching machine base (I-1), each connected to the base (I-1) via set screws (I-7). The clamping table (I-3) slides over the positioning shafts (I-2). The hydraulic cylinder's hydraulic spindle (I-4) is connected to the clamping table (I-3), and the cylinder body (I-5) is located outside the broaching machine base (I-1). One end of the broaching tool is connected to the clamping table (I-3). The tool extends through an opening in the broaching machine base (I-1). The hydraulic cylinder allows the clamping table (I-3) to move along the positioning shafts (I-2), simultaneously driving the tool's linear motion.

[0058] like Figure 3 As shown, a slot is located in the center of the clamping table (I-3). One end of the grinding tool is inserted into the slot and secured by a baffle (I-11). A pre-reserved oil hole is provided on the clamping table (I-3), through which an oil reservoir (I-9) is installed. The oil reservoir (I-9) is threadedly connected to the oil reservoir cap (I-10). The depth of the threaded connection adjusts the amount of lubricant delivered.

[0059] The hydraulic cylinder is connected to the hydraulic drive system III, such as Figure 6 and Figure 23 As shown, the hydraulic drive system III includes an oil tank III-3, a second drive motor III-2, an oil inlet pipe III-1, and an oil return pipe III-5. The oil tank III-3 is equipped with a three-position four-way electromagnetic reversing valve III-4, and the oil inlet pipe III-1 and the oil return pipe III-5 are connected through the three-position four-way electromagnetic reversing valve III-4. The oil inlet pipe III-1 and the oil return pipe III-5 are respectively connected to the hydraulic cylinder; the second drive motor III-2 drives the hydraulic pump to draw hydraulic oil from the oil tank III-3. After the hydraulic drive system receives the start signal, the second drive motor III-2 rotates forward, the three-position four-way electromagnetic reversing valve III-4 is energized to the left position, and the broaching machine processing speed is adjusted to the broaching speed; when the grinding start signal is received from the control system, the three-position four-way electromagnetic reversing valve III-4 is energized to the right position, and the broaching machine processing speed is adjusted to the grinding speed; when the stop signal is received from the control system, the three-position four-way electromagnetic reversing valve III-4 is de-energized to the right position and returns to the middle position, and the broaching machine stops; when the lifter V-1 is in place signal is received from the hydraulic cooling lifting system, the three-position four-way electromagnetic reversing valve III-4 is energized to the right position, and the second drive motor III-2 reverses to perform a rapid tool retraction operation.

[0060] like Figure 7As shown, the oil tank III-3 is connected to the control system IV, which includes an electrical box IV-1, position sensors, and wires IV-6. The electrical box IV-1 is fixed to the bracket I-6 and is equipped with a control switch IV-2. The position sensors are connected to the electrical box IV-1 via wires IV-6. The position sensors receive signals to control various operations of the broaching machine. In this embodiment, three position sensors are mounted on one side of the broaching machine base I-1. For ease of description, they are named according to their function: stop position sensor IV-3, grinding position sensor IV-4, and broaching position sensor IV-5. The broaching position sensor IV-5 is located near the mounting end of the turbine disk clamping device. The stop position sensor IV-3 is located at the other end of the broaching machine base I-1 (away from the mounting end of the turbine disk clamping device). The grinding position sensor IV-4 is located between the stop position sensor IV-3 and the broaching position sensor IV-5.

[0061] The position sensor in this embodiment can be capacitive, inductive, or mechanical, and can measure the position and speed of the broaching table I-3, which is used to control the grinding speed and stop. When the start button is pressed, the electrical box IV-1 sends a signal to the hydraulic drive system and the hydraulic cooling and lifting system. The hydraulic drive system adjusts the broaching speed to the broaching speed via the three-position, four-way solenoid reversing valve III-4. The hydraulic cooling and lifting system begins spraying coolant, and the broaching process begins. When the grinding position sensor IV-4 receives a signal, the electrical box IV-1 sends a signal to the hydraulic drive system, which adjusts the broaching speed to the grinding speed via the three-position, four-way solenoid reversing valve III-4, and the grinding process begins. When the stop position sensor IV-3 is energized, the electrical box IV-1 sends a signal to the hydraulic drive system, the hydraulic cooling and lifting system and the turbine disc clamping device, the hydraulic drive system stops working, the hydraulic cooling and lifting system stops spraying coolant and the lifter V-1 rises; then the turbine disc clamping device controls the first drive motor II-3 to rotate a predetermined angle, and at the same time the hydraulic drive system retracts the grinding knife through the three-position four-way electromagnetic reversing valve III-4. When the broaching position sensor IV-5 is energized, the electrical box IV-1 sends a signal to the hydraulic cooling and lifting system, and the lifter V-1 descends back to its original position, completing the overall control work.

[0062] like Figure 9As shown, the hydraulic cooling and lifting system V includes a hydraulic cooling box V-2, a lifter V-1, a cooling pipe V-5, a main oil pipe V-3, an auxiliary oil pipe V-4 and a third drive motor V-6. The hydraulic cooling box V-2 is fixed to the bracket I-6, the third drive motor V-6 is installed on the hydraulic cooling box V-2, and the third drive motor V-6 is installed with a hydraulic pump; the hydraulic cooling box V-2 is connected to one end of the cooling pipe V-5, the main oil pipe V-3 and the auxiliary oil pipe V-4, and the other ends of the cooling pipe V-5, the main oil pipe V-3 and the auxiliary oil pipe V-4 extend to the broaching machine base I-1 respectively, and the main oil pipe V-3 and the auxiliary oil pipe V-4 are connected to the lifter V-1. The lifter V-1 is installed in the hydraulic hole reserved in the broaching machine base I-1, as shown in FIG. Figure 9 As shown, the lifter V-1 is an existing structure, which is used to lift the turbine disk clamping device II; the other end of the cooling pipe V-5 corresponds to one side of the turbine disk clamping device II, and is used to cool the turbine disk II-4.

[0063] After the hydraulic cooling lifting system V receives the start signal from the control system, the third drive motor V-6 rotates forward and the cooling pipe V-5 sprays coolant; when it receives the stop signal, the hydraulic cooling box V-2 controls the cooling pipe V-5 to stop spraying coolant and lifts the lifter V-1 to the specified height; when it receives the signal that the grinding knife is in place, the third drive motor V-6 reverses and drives the lifter V-1 to return to the specified initial position.

[0064] like Figure 5 As shown, turbine disc clamping device II is mounted on one end of the broaching machine base I-1, above the broaching blade. Turbine disc clamping device II includes a guide II-1 and a teach pendant II-7. Guide II-1 is mounted on the broaching machine base I-1, and a through hole for mounting guide II-1 is located above the opening of the base I-1. Guide II-1 defines a guide slot, through which the broaching blade passes and connects to the clamping table I-3. A fixed table II-2 is mounted above guide II-1. A first drive motor II-3 is mounted on one side of fixed table II-2 and connected to turbine disc II-4 on the other side of fixed table II-2. Turbine disc II-4 is connected to the motor shaft via a connecting sleeve II-5, a flange II-6, and multiple screws.

[0065] The fixed table II-2 is mounted above the broaching machine base I-1 and guide II-1 and can be raised by the lifter V-1. The teach pendant II-7 is connected to the first drive motor II-3 via wire IV-6. After the turbine disc II-4 is installed, the driver is programmed via the teach pendant II-7. After machining a mortise and tenon groove, the turbine disc clamping device is raised via the lifter V-1. When it reaches the designated position, the lifter V-1 stops. The teach pendant II-7 receives a stop signal and issues a command to activate the first drive motor II-3, which stops after rotating a designated distance. Upon receiving a signal to return the broaching blade to its initial position, the lifter V-1 descends back to its original position, and the process repeats.

[0066] The broaching and grinding tool is an integrated broaching and grinding tool, which is made of materials with good properties such as high hardness, wear resistance, high strength, high toughness, heat resistance and impact resistance. It is divided into two parts, namely the broaching part VI-1 and the grinding part VI-2. Figure 10 As shown, the broaching section VI-1 is positioned in front, and the grinding section VI-2 is positioned in the back. It should be noted that the terms "front" and "back" in this embodiment are relative to the actual machining direction. A transition zone VI-3 is provided between the broaching section VI-1 and the grinding section VI-2. This transition zone VI-3 comprises a first and second segment, arranged sequentially. The first segment, which does not participate in machining but serves only to connect with the broaching section VI-1, employs a ribbed structure. The second segment adopts a continuous, progressive structure, identical in shape to the grinding section VI-2 but smaller than the post-broaching mortise groove to prevent excessive impact between the mortise groove and the grinding section.

[0067] The broaching tool part VI-1 is divided into two parts: the triangular rough grooving part and the semi-finishing contour grooving part. The triangular rough grooving part adopts a step-by-step transition method to broach a triangular groove; the semi-finishing contour grooving part adopts a two-side progressive transition method to broach the triangular groove into the shape of the processed groove, such as the turbine disk II-4 mortise and tenon groove. Figure 13 The longitudinal tree-shaped mortise and tenon grinding tool and gear groove shown are as follows Figure 14 The gear groove grinding tool and sprocket groove shown in the figure are Figure 15 The keyway is grinded and the machining allowance is 2mm after machining is completed.

[0068] The grinding part VI-2 can be divided into the excess removal part and the surface finishing part, which can be divided into Figure 11 The overall margin shown is removed and trimmed, as shown Figure 12 The allowance removal part adopts a continuous progressive transition structure to remove the broaching allowance, and the trimming part adopts a constant size structure to trim surface burrs and ensure surface smoothness.

[0069] The grinding section VI-2 includes the tool base and abrasive grains, which are either diamond or cubic boron nitride (CBN). The grains are arranged in various ways, either randomly or in an ordered pattern, and are secured to the tool base by brazing, electroplating, or resin bonding. The tool base is manufactured with an accuracy that is one to two grades higher than the mortise and tenon groove's positional accuracy, ensuring the final mortise and tenon groove meets or exceeds design requirements. The grinding section gradually increases in size and then remains constant.

[0070] like Figure 16 As shown in , the abrasive particles are arranged in an array on the surface of the tool substrate; Figure 17 As shown in , the abrasive particles are arranged in a staggered manner on the surface of the tool substrate; Figure 18 As shown, the abrasive grains are arranged in segments. This embodiment uses different abrasive grain arrangements. The array arrangement and staggered arrangement mimic the conventional grinding wheel method. The segmented arrangement of coarse and fine abrasive grains solves the problem of traditional grinding wheels with single abrasive grains and fixed machining accuracy. The entire process from semi-finishing to finishing grinding can be completed in one go, ensuring machining accuracy.

[0071] The grinding part VI-2 is provided with a chip removal groove, such as Figure 19 As shown, the chip removal grooves of the grinding part VI-2 are straight chip removal grooves with equal spacing; Figure 20 As shown, the chip grooves are distributed evenly with inclined chip grooves; Figure 21 As shown, the chip grooves are distributed evenly with triangular chip grooves; Figure 22 As shown, the chip grooves are equidistantly distributed using triangular chip grooves that alternate in positive and negative directions. This embodiment uses chip grooves of different shapes. The straight chip grooves and the oblique chip grooves imitate the traditional chip groove style. The triangular chip grooves and the triangular chip grooves that alternate in positive and negative directions solve the problem of uneven transition between the two sections of the grinding wheel before and after traditional chip groove grinding. The triangular progressive transition method ensures the continuity of the grinding process. Compared with traditional grinding wheel grinding, the chip groove structure solves the problem of chip accumulation and clogging of the grinding wheel, ensures that the chips can be discharged smoothly, and has the characteristics of improving processing quality, avoiding excessive wear of abrasive particles, and good grinding transition.

[0072] This embodiment solves the problem of requiring a change in machining methods during the integrated machining of the turbine disk II-4 mortise, keyway, and gear slot. From rough forming to fine finishing and polishing, a single device can be used to complete the process without changing machining methods. This meets the needs of integrated machining of workpieces with varying machining shapes (such as the turbine disk II-4 mortise, keyway, and gear slot). The simple structure, easy assembly, and ease of operation avoid excessive modification of the broaching machine, facilitate integration with conventional broaching machines, reduce program editing complexity, and lower machining costs.

[0073] Example 2:

[0074] This embodiment provides a processing technology for a broaching and grinding integrated tool system, using the broaching and grinding integrated tool system described in Example 1, including the following steps:

[0075] Step 1: Clean the broaching machine base I-1, chip tray I-8, clamping table I-3, turbine disc clamping device II and broaching sharpener.

[0076] Step 2: Install the turbine disk II-4 to be ground on the turbine disk clamping device II, and ensure that the parallelism between the turbine disk II-4 and the fixed table II-2 is less than 10μm; and connect the grinding tool through the guide II-1 and the clamping table I-3, ensuring that the runout of the grinding tool during feeding is less than 5μm; adjust the position of each position sensor to ensure that the position error of the grinding section designed with the grinding tool is less than 2mm.

[0077] Step 3: Use the programming software to program the grinding process, determine the grinding parameters, and perform the integrated grinding and grinding process of the tenon of turbine disc II-4. First, perform the grinding process while spraying coolant, then perform the grinding process until the tenon processing accuracy reaches the required accuracy. Then, stop the above actions and lift turbine disc II-4. The grinding cutter hydraulic drive system then returns to its initial position. At the same time, the first drive motor II-3 drives turbine disc II-4 to rotate a certain angle (the rotation angle is 360 degrees divided by the number of tenons on turbine disc II-4). Then, turbine disc II-4 descends and the grinding process of the next tenon begins. This cycle continues until all tenon grinding processes are completed.

[0078] Among them, the grinding process, the lifting action of the turbine disk II-4 and the retraction stop are determined by the position sensor signal. When the grinding position sensor IV-4 receives a signal, the grinding process starts; when the stop position sensor IV-3 receives a signal, the lifter V-1 is started; when the broaching position sensor IV-5 receives a signal, the retraction stops.

[0079] The broaching and grinding parameters include broaching feed speed, grinding feed speed, cutting depth and grinding depth, which are determined according to the turbine disk II-4 material and the mortise and tenon processing requirements; the hydraulic spindle I-4 feed speed in the broaching stage is set to 2-7m / min; the cutting depth is set to 0.1-1mm; the hydraulic spindle I-4 feed speed in the grinding stage is set to 2-80m / s; and the grinding depth is set to 0.005-0.5mm / s.

[0080] The above description is merely a preferred embodiment of the present application and is not intended to limit the present application. Various modifications and variations are possible for those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present application shall be included within the scope of protection of the present application.

Claims

1. A broaching and grinding integrated tool system, characterized in that: include: The broaching machine assembly includes a broaching machine base, a clamping platform provided in the broaching machine base, a broaching and sharpening tool mounted on the clamping platform, and the clamping platform connected to a tractor mechanism; a plurality of position sensors are installed on one side of the broaching machine base, and the position sensors are used to obtain position information of the clamping platform; the broaching and sharpening tool includes a broaching tool portion and a sharpening tool portion connected as one body; The turbine disc clamping device comprises a turbine disc driving mechanism for mounting the turbine disc, wherein a lifter is provided between the turbine disc driving mechanism and the broaching machine base; The push-pull mechanism includes a hydraulic cylinder, the clamping platform is connected to the hydraulic cylinder, and the hydraulic cylinder is connected to the hydraulic drive system; A positioning shaft is installed in the base of the broaching machine, and the clamping platform is in sliding cooperation with the positioning shaft; The lifter is connected to a hydraulic cooling and lifting system, and both the hydraulic cooling and lifting system and the hydraulic drive system are connected to a control system; A broaching position sensor, a grinding position sensor, and a stop position sensor are installed on one side of the broaching machine base; the control system is used to control the hydraulic drive system to stop working according to the detection signal of the stop position sensor, control the broaching machine speed to be adjusted to the grinding speed according to the detection signal of the grinding position sensor, and control the broaching machine speed to be adjusted to the broaching speed according to the detection signal of the broaching position sensor; A transition zone is provided between the broaching portion and the grinding portion, and the transition zone includes a first section and a second section arranged in sequence, wherein the first section is used to connect with the broaching portion, and the second section is used to connect with the grinding portion, and has the same shape as the grinding portion; The broaching part is divided into a rough grooving part and a semi-finishing contour grooving part; the rough grooving part is used to broach a triangular groove, and the semi-finishing contour grooving part is used to broach the triangular groove into a turbine disc tenon groove, a gear groove or a sprocket groove.

2. The broaching and grinding integrated tool system according to claim 1, characterized in that: The sharpening part comprises a tool base and abrasive grains distributed on the surface of the tool base; the abrasive grains are arranged in a disordered manner or in an ordered manner.

3. The broaching and grinding integrated tool system according to claim 1 or 2, characterized in that: The grinding part is provided with a chip groove, and the chip groove is a straight chip groove, an oblique chip groove, a triangular chip groove or a triangular chip groove that alternates positive and negative directions.

4. A processing technology for a broaching and grinding integrated tool system according to any one of claims 1 to 3, characterized in that: include: Install the turbine disc to be ground on the turbine disc clamping device and install the grinding tool; According to the broaching and grinding parameters, the turbine disc tenon and groove are subjected to an integrated broaching and grinding process, wherein each groove is first broached and then ground.

5. The processing technology of the integrated broaching and grinding tool system according to claim 4, characterized in that: When the grinding position sensor receives a signal, the grinding process starts; when the stop position sensor receives a signal, the lifter is started; when the broaching position sensor receives a signal, the tool retraction stops.

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