Processing method of large-size mortise and tenon for extra-thick and large-size wheel

Abstract

The invention discloses a method for processing large-size mortise and tenon grooves of an ultra-thick and large-size wheel disc, and relates to the technical field of processing mortise and tenon grooves of a wheel disc, and includes the following specific steps: step one: forging inspection upon entry; step two: semi-finishing turning; step three: finishing turning; step four: turning a projection test disc; step five: corrosion inspection; step six: drilling a positioning connection hole of the wheel disc; step seven: cutting a projection disc; step eight: cutting a test pull disc; step nine: broaching the test pull disc and the projection disc; step ten: wire cutting a rough cut of the wheel disc mortise and tenon groove; step eleven: drawing the mortise and tenon groove; step twelve: chamfering the tip edge of the mortise and tenon groove; step thirteen: coloring inspection. The method for processing large-size mortise and tenon grooves of an ultra-thick and large-size wheel disc adopts wire cutting and broaching to process the mortise and tenon grooves, and only 22 broaches are needed to complete the mortise and tenon groove processing, which can save a lot of costs and save the manufacturing cycle of the broaches. The scheme is to use an electric machining device (fast wire) to only roughly cut the mortise and tenon grooves, cut one and trim one; and then use a broach to broach, so as to meet the requirements of the design drawing.

Description

Technical Field

[0001] The invention relates to the technical field of wheel disc tenon and groove processing, and in particular to a method for processing large-size tenon and groove of an ultra-thick and large-size wheel disc. Background Art

[0002] As the crown jewel of the world's industrial field, the core technology of gas turbines has always been monopolized by foreign companies. The core component of a gas turbine is the rotor, and the processing of the tenon groove of the rotor wheel is the key to the processing of the gas turbine rotor. Without increasing the investment, the old crawler broaching machine was used to design a special fixture to solve the broaching of the wheel birch groove. The processed birch groove has a very good indexing and high quality.

[0003] The original processing method of the wheel disc is to use a broach. Because the wheel disc has a large diameter, a thick rim, and a large mortise and tenon profile, a complete set of broaches is required for broaching. The manufacturing cost of the broach is extremely high, which indirectly increases the processing cost of the wheel disc. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention provides a method for processing large-size mortise and tenon grooves of ultra-thick, large-size wheel discs, which solves the problems raised in the above-mentioned background technology.

[0005] To achieve the above purpose, the present invention is implemented by the following technical scheme: a method for processing large-size mortise and tenon grooves of an ultra-thick, large-size wheel disc, comprising the following specific steps:

[0006] Step 1: Inspection of forgings upon arrival at the factory. Re-inspect the forging blanks upon arrival at the factory to check whether the forging dimensions are consistent with the blank design drawings, and remove forgings that do not meet the dimensions requirements.

[0007] Step 2: Semi-finishing machining;

[0008] Step 3: Finishing machining;

[0009] Step 4: Turn the projection test plate. Use a lathe to process the projection test plate for projection inspection. The thickness of the processed projection test plate must be consistent with the thickness of the part;

[0010] Step 5: Corrosion inspection: Use sodium hydroxide solution to coat the surface of the wheel profile and conduct corrosion inspection to check whether there are defects and recrystallization on the surface of the parts. If there are no defects and recrystallization on the surface of the parts, proceed to the next step of processing. If there are defects and recrystallization, remove them;

[0011] Step 6: Processing positioning connection holes on the surface of the wheel disc;

[0012] Step 7: Cut the projection plate. After clamping the projection plate on the broaching machine fixture, cut the two mortise contours according to the finished mortise size with a 0.1-2mm margin.

[0013] Step 8: Cut the test pull plate. After clamping the test pull plate on the broaching machine fixture, cut the outlines of the four mortises according to the finished size of the mortise and tenon with a reserve of 0.1-2mm;

[0014] Step 9: Broach the test plate and projection plate, draw two mortises on the test plate in the order of the broach, and inspect the mortise size, contour and surface roughness; broach the projection plate and perform optical projection inspection on the mortise size and contour of the projection plate, compare the error between the mortise contour of the projection plate and the rated contour, select qualified workpieces for the next step of processing, and rework unqualified workpieces;

[0015] Step 10: Use wire cutting equipment to roughly process the tenon groove of the cutting wheel;

[0016] Step 11: Tenon drawing. After the projection and the test pull plate are qualified, the evenly distributed tenon grooves of the wheel disc are broached in the order of the broaching tool; the outline dimensions of the tenon groove are tested by a roller and a go / no-go gauge;

[0017] Step 12: Round the sharp edges of the mortise and tenon grooves, and round and polish the sharp angles of the end faces of the grooves according to the design standards;

[0018] Step 13: Color inspection: Use penetrant to perform color inspection on the mortise and tenon parts to avoid cracks in the mortise and tenon parts;

[0019] Step 14: Milling the hanging ear slot, using a milling machine to process the hanging ear slot and expand the hole;

[0020] Step 15: Bench rounding, polishing and marking: rounding and polishing the mortise and tenon after milling and marking according to specifications;

[0021] Step 16: Fine-tune the surface dimensions of the wheel disc;

[0022] Step 17: Use a lathe to process and remove the process construction table;

[0023] Step 18: Conduct visual inspection on the finished wheel disc after processing;

[0024] Step 19: Storage.

[0025] Optionally, the semi-finishing turning process in step 2 is specifically as follows:

[0026] (1) Semi-finishing the rear end of the wheel disc. The rear end of the wheel disc is semi-finished to remove the excess, leaving a 0.1-0.2mm margin for the size position;

[0027] (2) Semi-finishing the front end of the wheel disc: The front end of the wheel disc is semi-finished to remove the excess, leaving a 0.1-0.2mm margin for the size position.

[0028] Optionally, the finishing process in step 3 is as follows:

[0029] (1) Fine-finishing the wheel disc datum: Before fine-machining, the surface of the wheel disc is fine-finished on a lathe to determine the datum surface;

[0030] (2) Fine-tune the front web profile of the wheel disc;

[0031] (3) Fine-tune the rear end web profile of the wheel disc and leave a precision fit margin of 0.1-0.3mm.

[0032] Optionally, in the step 10, the wheel disc is cut by evenly distributing the outline of the mortise and tenon according to the finished size of the mortise and tenon by leaving a 0.5-2mm margin, and the position and size of the mortise and tenon after the wire cutting are checked with a checking fixture adapter.

[0033] The present invention provides a method for processing large-size mortise and tenon grooves of an ultra-thick, large-size wheel disc, which has the following beneficial effects:

[0034] This method for processing large-size mortise and tenon of ultra-thick, large-size wheel discs adopts wire cutting and broaching to process the mortise and tenon. Only 22 broaches are needed to complete the mortise and tenon processing. Compared with the current demand for broaches in processing, the cost of using broaches is greatly reduced, which directly reduces the processing cost of the wheel disc processing process. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 It is a schematic diagram of the structure of the parts product in the invention;

[0036] Figure 2 It is a schematic diagram of the position structure of the tenon groove in the wheel disc in the invention;

[0037] Figure 3 It is a schematic diagram of the rough structure of the tongue and groove wire cutting in the invention;

[0038] Figure 4 It is a schematic diagram of the maximum outline structure of the mortise and tenon in the invention;

[0039] Figure 5 It is a schematic diagram of the minimum outline structure of the mortise and tenon in the invention;

[0040] Figure 6 It is a schematic diagram of the theoretical outline structure of the mortise and tenon in the invention. DETAILED DESCRIPTION

[0041] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0042] See also Figures 1 to 6 The present invention provides a technical solution: a method for processing large-size mortise and tenon grooves of an ultra-thick, large-size wheel disc, comprising the following specific steps:

[0043] Step 1: Inspection of forgings upon arrival at the factory. Re-inspect the forging blanks upon arrival at the factory to check whether the forging dimensions are consistent with the blank design drawings, and remove forgings that do not meet the dimensions requirements.

[0044] Step 2: Semi-finishing machining, as follows:

[0045] (1) Semi-finishing the rear end of the wheel disc to remove the allowance and reserve a 0.15mm allowance for the size position;

[0046] (2) Semi-finishing turning the front end of the wheel disc to remove most of the margin (only 0.15mm margin is reserved for important dimensional positions);

[0047] Step 3: Finishing machining, such as Figure 1 As shown, the details are as follows:

[0048] (1) Fine-finishing the wheel disc datum: Before fine-machining, the surface of the wheel disc is fine-finished on a lathe to determine the datum surface;

[0049] (2) Fine-tune the front web profile of the wheel disc;

[0050] (3) Fine-tune the rear end web profile of the wheel disc and reserve a precision fit margin of 0.15 mm;

[0051] Step 4: Turn the projection test plate, turn the projection plate used for projection inspection, and make the thickness of the projection test plate consistent with the thickness of the part, such as Figure 2 As shown;

[0052] Among them, the line P in the figure refers to the center line of the wheel disc, the angle between the center line of the wheel disc and the center line of the tenon groove is set to 23°, the distance between the intersection of the center line of the wheel disc and the center line of the tenon groove and the left end face is 58mm, and the center line of the blade root tenon groove in the figure passes through the center of the circle of ∅1240mm;

[0053] Step 5: Corrosion inspection: Use sodium hydroxide solution to coat the surface of the wheel profile and conduct corrosion inspection to check whether there are defects and recrystallization on the surface of the parts. If there are no defects and recrystallization on the surface of the parts, proceed to the next step of processing. If there are defects and recrystallization, remove them;

[0054] Step 6: Drill the wheel positioning connection hole. The connection hole position is as follows: Figure 1 As shown;

[0055] Step 7: Cut the projection plate. Clamp the projection plate on the broaching machine fixture and cut the two mortise contours according to the finished mortise size with a 1mm margin. Figure 3 As shown;

[0056] Step 8: Cut the test pull plate. Clamp the test pull plate on the broaching machine fixture and cut the outline of 4 mortises (52 grooves are evenly distributed) according to the finished size of the mortise and tenon grooves with a 1mm margin. Figure 3 As shown;

[0057] in,

[0058] The spacing of the mortise and tenon contours is 36.681mm, the symmetry tolerance range is 0.05mm, C is the tolerance value, the thick solid line in the figure is the wire cutting contour, the double-dotted line is the product theoretical contour, and the spacing between the wire cutting contour and the product theoretical contour is 1±0.02mm;

[0059] Step 9: Broach the test plate and projection plate, draw two mortises on the test plate in the order of the broach, and inspect the mortise size, contour and surface roughness; broach the projection plate and perform optical projection inspection on the mortise size and contour of the projection plate, compare the error between the mortise contour of the projection plate and the rated contour, select qualified workpieces for the next step of processing, and rework unqualified workpieces;

[0060] Step 10: Wire cutting to roughly cut the wheel tenon groove. Cut the wheel to make 52 evenly spaced tenon groove contours with a 1mm margin according to the finished tenon groove size, and use a gauge adapter to check the position and size of the tenon groove after wire cutting. Figure 4 and Figure 5 As shown, the outer contour in the figure is the maximum allowable contour, and the inner contour is the theoretical contour;

[0061] in,

[0062] Figure 4 and Figure 5 In the example, the spacing of a single tenon is 16mm, the top arc radius of the tenon profile at both sides is 3.376mm, the arc angle is 52.28°, and the depth of the tenon is 4.99mm; the included angle of the symmetrical tenon profiles on both sides is 38°, and the top profile spacing is 16.521mm;

[0063] Step 11: Tenon drawing. After the projection and the test drawing disc are qualified, the 52 evenly distributed tenons of the wheel disc are drawn in the order of the broach. The outline dimensions of the tenon are tested with a roller and a go / no-go gauge.

[0064] Step 12: Round the sharp edges of the mortise and tenon grooves, and round and polish the sharp angles of the end faces of the grooves according to the dimensions of the design drawing;

[0065] Step 13: Color inspection: Use penetrant to perform color inspection on the mortise and tenon parts. No cracks are allowed.

[0066] Step 14: Milling the hanging ear slots, milling 52 hanging ear slots and expanding the holes;

[0067] Step 15: Fitter rounding, polishing and marking: rounding and polishing the mortise and tenon after milling and marking as required;

[0068] Step 16: Fine-tune the rear end and the precise dimensions of the rear end;

[0069] Step 17: Remove the construction table and lathe the process construction table;

[0070] Step 18: Inspection, the finished roulette wheel is finally inspected and the following is obtained: Figure 6 The wheel with the theoretical outline of the mortise and tenon shown, the parameters in the figure are all in mm;

[0071] Step 19: Storage.

[0072] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A method for processing large-size mortise and tenon grooves of ultra-thick and large-size wheel discs, characterized in that: The specific steps include: Step 1: Inspection of forgings upon arrival at the factory. Re-inspect the forging blanks upon arrival at the factory to check whether the forging dimensions are consistent with the blank design drawings, and remove forgings that do not meet the dimensions requirements. Step 2: Semi-finishing machining, as follows: (1) Semi-finishing the rear end of the wheel disc. The rear end of the wheel disc is semi-finished to remove the excess, leaving a 0.1-0.2mm margin for the size position; (2) Semi-finishing the front end of the wheel disc: the front end of the wheel disc is semi-finished to remove the excess, and a 0.1-0.2mm margin is reserved for the size position; Step 3: Finishing machining, as follows: (1) Fine wheel disc datum: Before fine machining, the surface of the wheel disc is fine-tuned by lathe to determine the datum surface; (2) Fine-finishing the front web profile of the wheel disc; (3) Fine-tune the rear end web profile of the wheel disc and reserve a precision fit margin of 0.1-0.3mm; Step 4: Turn the projection test plate. Use a lathe to process the projection test plate for projection inspection. The thickness of the processed projection test plate must be consistent with the thickness of the part; Step 5: Corrosion inspection: Use sodium hydroxide solution to coat the surface of the wheel profile and conduct corrosion inspection to check whether there are defects and recrystallization on the surface of the parts. If there are no defects and recrystallization on the surface of the parts, proceed to the next step of processing. If there are defects and recrystallization, remove them; Step 6: Processing positioning connection holes on the surface of the wheel disc; Step 7: Cut the projection plate. After clamping the projection plate on the broaching machine fixture, cut the two mortise contours according to the finished mortise size with a 0.1-2mm margin. Step 8: Cut the test pull plate. After clamping the test pull plate on the broaching machine fixture, cut the outlines of the four mortises according to the finished size of the mortise and tenon with a reserve of 0.1-2mm; Step 9: Broach the test plate and projection plate, draw two mortises on the test plate in the order of the broach, and inspect the mortise size, contour and surface roughness; broach the projection plate and perform optical projection inspection on the mortise size and contour of the projection plate, compare the error between the mortise contour of the projection plate and the rated contour, select qualified workpieces for the next step of processing, and rework unqualified workpieces; Step 10: Use wire cutting equipment to roughly process the tenon groove of the cutting wheel; Step 11: Tenon drawing. After the projection and the test pull plate are qualified, the evenly distributed tenon grooves of the wheel disc are broached in the order of the broaching tool; the outline dimensions of the tenon groove are tested by a roller and a go / no-go gauge; Step 12: Round the sharp edges of the mortise and tenon grooves, and round and polish the sharp angles of the mortise and tenon groove end faces according to the design standards; Step 13: Color inspection: Use penetrant to perform color inspection on the mortise and tenon parts to avoid cracks in the mortise and tenon parts; Step 14: Milling the hanging ear slot, using a milling machine to process the hanging ear slot and expand the hole; Step 15: Bench rounding, polishing and marking: rounding and polishing the mortise and tenon after milling and marking according to specifications; Step 16: Fine-tune the surface dimensions of the wheel disc; Step 17: Use a lathe to process and remove the process construction table; Step 18: Conduct visual inspection on the finished wheel disc after processing; Step 19: Storage.

2. The method for processing large-size mortise and tenon grooves of an ultra-thick, large-size wheel disc according to claim 1 is characterized in that: In the step 10, the wheel disc is cut by wire cutting the wheel disc according to the finished size of the mortise and tenon with a reserve of 0.5-2mm, and the position and size of the mortise and tenon after wire cutting are checked with a checking fixture adapter.

Images