Aero-engine part grinding machining forward process design method

Abstract

The invention relates to the technical field of aero-engine machining, in particular to an aero-engine part grinding machining forward process design method which comprises the steps that S1, grinding machining machinability is analyzed, and a certain link needing grinding machining in the part machining process is determined; s2, according to a certain link needing to be ground, a preliminary part machining process scheme is designed; s3, simulation analysis is conducted on the preliminary part machining process scheme, and the part machining process scheme is optimized for the first time according to a simulation analysis result; s4, on-site verification is conducted on the part machining process scheme optimized for the first time, and a part machining process scheme optimized for the second time is conducted according to comparison between a detection evaluation result obtained after machining and corresponding data in simulation; and S5, forming a part machining process procedure according to the part machining process scheme optimized for the second time. The grinding process stability and the product percent of pass are improved, the trial and error cost is reduced, and dependence on experience of operators in traditional grinding is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of aviation engine mechanical processing, and in particular to a forward process design method for aviation engine part grinding processing. Background Art

[0002] Aircraft engines are known as the "crown jewel" of modern industry, among which difficult-to-process materials such as nickel-based cast high-temperature alloys are widely used in aircraft engines. Due to the high quality requirements of nickel-based cast high-temperature alloy parts required for aircraft engines and the difficulty in precision molding of special-shaped structures, grinding is generally used for processing. However, at present, grinding processing mainly relies on human skills and experience to participate in control. According to traditional experience, the process is copied, and the grinding process is repeatedly tested. The trial and error method is used, which has high processing costs, poor stability of the surface quality of the parts after processing, and the part processing process is also unstable. The reproducibility of parts with the same quality requirements is poor, which seriously restricts the development progress of aircraft engine parts. Summary of the invention

[0003] In view of the shortcomings of the prior art, the present invention provides a forward process design method for grinding of aircraft engine parts, which can improve the stability of the grinding process, reduce the cost of trial and error, and ensure the reproducibility of parts with the same quality requirements.

[0004] In order to achieve the above object, the technical solution of the present invention is:

[0005] A forward process design method for grinding of aircraft engine parts comprises the following steps:

[0006] S1: Grinding process feasibility analysis, determine the link that needs grinding process in the part processing process;

[0007] S2: Design a preliminary part processing solution based on a process that requires grinding;

[0008] S3: Perform simulation analysis on the preliminary part processing technology plan, and optimize the part processing technology plan for the first time based on the simulation analysis results;

[0009] S4: Conduct on-site verification of the first optimized part processing technology plan, and conduct a second optimized part processing technology plan based on the comparison of the post-processing inspection and evaluation results with the corresponding data in the simulation;

[0010] S5: The second optimized part processing process plan is formed into a part processing process specification.

[0011] Furthermore, S1 includes: using software to establish a three-dimensional model of the process, using family part geometric features, using machinability analysis software to identify part geometric features, and performing grinding machinability analysis on the parts, obtaining a grinding machinability analysis report, and determining a link in the part machining process that requires grinding.

[0012] Furthermore, S2 includes:

[0013] S2.1: Part process design;

[0014] S2.2: Develop component dimension inspection plan;

[0015] S2.3: Use offline programming tools to compile CNC machining programs.

[0016] Furthermore, S2.1 includes: the part process step design designs the part processing technology based on the part geometric characteristics, grinding process standards, and grinding wheel selection standards; the part process step design includes equipment selection, fixture selection, roller scheme design and grinding wheel selection, and enables tools to select appropriate equipment, fixtures, rollers, and grinding wheels from the equipment library, tooling library, roller library, and grinding wheel library included in the resource library, and determine the roller design scheme; the part process step design also includes selecting processing parameters from the process basic database.

[0017] Furthermore, S2.3 includes: the offline programming tool calls the process basic database and the equipment library, tooling library, roller library, grinding wheel library and feature model library in the resource library through the enabling tool, and selects and extracts according to the data covering boundary conditions, process programming strategies, feature processing programming strategies, and the equipment library, tooling library, roller library, grinding wheel library and feature model library corresponding to the equipment, fixtures, rollers, grinding wheels and geometric features, as well as the processing parameters, tool parameters, processing strategies and processing plans in the process basic database, establishes a dimensional variable calculation model, and realizes the compilation of CNC processing programs.

[0018] Furthermore, in S3, the CNC machining program is simulated, and the simulation analysis includes geometric simulation and physical simulation; the geometric simulation, through an enabling tool, calls the machine tool, control system, tool model, workpiece model, blank model, and machining program required by the geometric simulation library into the geometric simulation software for collision, interference, overcutting, and undercutting analysis; the physical simulation includes machining deformation simulation and surface quality simulation; the part model is meshed, the load type is defined, the material properties are input, the boundary conditions are set, and the finite element solution is performed through the physical simulation tool to realize the physical simulation of the residual stress and temperature field of the grinding process.

[0019] Furthermore, S4 includes: performing actual processing according to the part process step design; selecting parts with typical characteristics and processing them through a grinding machine according to the first optimized part processing process plan, inspecting and evaluating the geometric accuracy and surface integrity indicators of the processed parts according to the part size inspection plan, and analyzing the grinding wheel wear. According to the inspection and evaluation results and the comparison of the grinding wheel wear with the corresponding data in the simulation, the part processing process plan is optimized for the second time.

[0020] Furthermore, the entire processing process of S4 is monitored by a real-time monitoring system, which is electrically connected to a control system, and the control system is electrically connected to the machine tool; the real-time monitoring system monitors the processing process in real time, collects power, vibration, temperature and coolant flow process data of the processing process, feeds the process data back to the control system, and issues instructions to the processing equipment through the control system, so as to optimize the processing process in real time and meet the processing quality requirements.

[0021] Furthermore, the inspection and evaluation includes part size inspection and evaluation, grinding surface integrity inspection and evaluation, grinding tool evaluation and grinding system evaluation; wherein, the grinding surface integrity inspection and evaluation includes surface roughness inspection, surface / subsurface damage inspection, residual stress inspection, burn and chatter mark inspection and evaluation; the grinding tool evaluation includes grinding wheel wear form evaluation and grinding wheel life evaluation; the grinding system evaluation includes spindle power, temperature and machine vibration evaluation.

[0022] Furthermore, the parts with typical features are blade edge plates, tenons or blade crowns.

[0023] The beneficial effects of the present invention are:

[0024] The present invention uses the above-mentioned forward process design method, starts with the analysis of the machinability of grinding, simulates the part design process, and then conducts actual verification and optimization. It can be applied to the grinding of the tenon / edge plate of the blade, and simulates the dimensional accuracy and surface integrity after processing; the present invention supports the digital and intelligent development of grinding, improves the digital and intelligent level of the grinding process, improves the stability of the grinding process and the product qualification rate, reduces the trial and error cost, and can reduce the dependence on the operator's experience in traditional grinding; at the same time, the present invention also has broad market demand and application prospects for promoting the intelligent development of the grinding process of products such as gas turbines and marine thrusters. The use of the present invention can improve process consistency, reduce scrap rate, and save costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 A flow chart of a forward process design method for grinding of aircraft engine parts according to the present invention;

[0026] Figure 2 It is a flow chart of the preliminary parts processing process scheme of the present invention. DETAILED DESCRIPTION

[0027] In order to better explain the present invention and facilitate understanding, the technical solutions and effects of the present invention are described in detail below through specific implementation modes in conjunction with the accompanying drawings.

[0028] like Figure 1 As shown, this embodiment discloses a forward process design method for grinding of aircraft engine parts, and the specific steps are as follows:

[0029] S1: Perform grinding machinability analysis to determine a link in the part processing process that needs grinding. The part material is nickel-based cast high-temperature alloy.

[0030] Use software to build a three-dimensional model of the process. Based on the three-dimensional model of the process and the structural characteristics of the family parts, use machinability analysis software to identify the geometric features of the parts, perform machinability analysis, and determine a link in the part machining process that requires grinding.

[0031] Specifically, use UG software to establish a three-dimensional model of the process, import the three-dimensional model of the process into the machinability analysis software, and input the geometric features of the family parts into the machinability analysis software; use the geometric features of the family parts to identify the geometric features of the parts using the machinability analysis software, and use the design file library, standard library, and grinding machinability rule library in the resource library embedded in the machinability analysis software to perform grinding machinability analysis of the parts, where the standard library includes processing standards for parts or part materials, specifically enterprise standards, national standards, and industry standards; obtain a grinding machinability analysis report to determine a link in the part machining process that requires grinding.

[0032] S2: Design a preliminary parts processing plan based on the process that needs grinding;

[0033] like Figure 2 As shown, the preliminary part processing technology plan includes:

[0034] S2.1: Part process design

[0035] The part process step design designs the part processing procedures according to the part geometric features, grinding process standards, and grinding wheel selection standards, and the process step design includes equipment selection, fixture selection, roller scheme design and grinding wheel selection. The enabling tool selects appropriate equipment, fixtures, rollers, grinding wheels, etc. from the equipment library, tooling library, roller library, and grinding wheel library included in the resource library to determine the diamond roller design scheme; and selects reasonable processing parameters from the process basic database, including grinding wheel linear speed, feed speed, grinding depth, grinding wheel dressing rate, dressing speed ratio and corresponding spindle power and vibration.

[0036] S2.2: Develop component dimension inspection plan;

[0037] S2.3: Use offline programming tools to compile CNC machining programs;

[0038] Specifically, the offline programming tool calls the process basic database and resource library through the enabling tool; the process basic database includes data covering boundary conditions, process programming strategies, feature processing programming strategies, processing parameters, tool parameters, processing strategies and processing plans in the process basic database, such as the structure of blades and grinders, key dimensional variables, grinding wheel parameters, roller parameters, clamping tooling, grinding posture, process data of trajectory parameters, and the equipment, fixtures, rollers, grinding wheels, and geometric features corresponding to the equipment library, tooling library, roller library, grinding wheel library, and feature model library included in the resource library are selected and extracted to compile CNC machining programs, realize intelligent acquisition and transmission of process data, and offline rapid programming of grinding, and change the method that relies on manual work, work experience, and single-machine manual work.

[0039] S3: Perform simulation analysis on the preliminary part processing technology plan, and optimize the part processing technology plan for the first time based on the simulation analysis results;

[0040] Specifically, the CNC machining program is simulated, and the simulation analysis includes geometric simulation and physical simulation. Through geometric simulation and physical simulation, the feasibility of the process design scheme is judged, and the process design scheme is iteratively optimized. When the process design scheme needs to be optimized, the machining parameters in the process basic database are modified, and the equipment, fixtures, rollers, and grinding wheels in the resource library are reselected.

[0041] The geometric simulation and physical simulation can simulate parts according to material properties, process parameters, geometric features, and basic material data. The geometric simulation includes a geometric simulation environment; the physical simulation includes a grinding deformation simulation tool and a grinding heat simulation tool.

[0042] The geometric simulation, through the enabling tool, calls the machine tool, control system, tool model, workpiece model, blank model, processing program, etc. required by the geometric simulation library into the geometric simulation software for collision, interference, overcutting, undercutting, etc. analysis;

[0043] The physical simulation includes machining deformation simulation, surface quality simulation, etc.; the physical simulation tool is used to mesh the part model, define the load type, input material properties, set boundary conditions and perform finite element solution to achieve physical simulation of residual stress and temperature field of grinding machining.

[0044] S4: Conduct on-site verification of the first optimized part processing technology plan, and conduct a second optimized part processing technology plan based on the comparison of the post-processing inspection and evaluation results with the corresponding data in the simulation;

[0045] Specifically, actual processing is carried out according to the part process step design; blade crowns with typical characteristics are selected, and blade edge plates, tenons, etc. may also be selected and processed by grinding machines according to the first optimized part processing technology plan; the geometric accuracy and surface integrity indicators of the processed parts are inspected and evaluated according to the part size inspection plan, and the grinding wheel wear is analyzed; based on the inspection and evaluation results and the grinding wheel wear conditions, they are compared with the corresponding data in the simulation, and the part processing technology plan is optimized for the second time.

[0046] The inspection and evaluation includes part size inspection and evaluation, grinding surface integrity inspection and evaluation, grinding tool evaluation and grinding system evaluation, etc.; wherein, the grinding surface integrity inspection and evaluation includes surface roughness inspection, surface / subsurface damage inspection, residual stress inspection, burn and chatter mark inspection and evaluation, etc.; the grinding tool evaluation includes grinding wheel wear form evaluation, grinding wheel life evaluation, etc.; the grinding system evaluation includes spindle power, temperature and machine tool vibration evaluation, etc.

[0047] The entire machining process is monitored by a real-time monitoring system, which is electrically connected to a control system, and the control system is electrically connected to a machine tool; the real-time monitoring system monitors the machining process in real time, collects process data such as power, vibration, temperature and coolant flow rate of the machining process, feeds the process data back to the control system, and issues instructions to the machining equipment through the control system to optimize the machining process in real time to meet the machining quality requirements; at the same time, the process data is collected into a production data warehouse, and the grinding wheel linear speed, feed speed, grinding depth, grinding wheel dressing rate, dressing speed ratio and corresponding spindle power and vibration are extracted from the production data warehouse in a standardized manner, and entered into the process database as a supplement to the process basic database for calling by the offline programming tool.

[0048] S5: The second optimized part processing technology plan is formed into a part processing technology specification to guide the processing process.

Claims

1. A forward process design method for grinding of aircraft engine parts, characterized in that: The steps include: S1: Grinding process feasibility analysis, determine the link that needs grinding process in the part processing process; S2: Design a preliminary part processing solution based on a process that requires grinding; S3: Perform simulation analysis on the preliminary part processing technology plan, and optimize the part processing technology plan for the first time based on the simulation analysis results; S4: Conduct on-site verification of the first optimized part processing technology plan, and conduct a second optimized part processing technology plan based on the comparison of the post-processing inspection and evaluation results with the corresponding data in the simulation; S5: The second optimized part processing process plan is formed into a part processing process specification.

2. The forward process design method for grinding of aircraft engine parts according to claim 1 is characterized in that: S1 includes: Use software to build a three-dimensional process model, adopt the geometric features of family parts, use machinability analysis software to identify the geometric features of parts, and perform grinding machinability analysis on parts to obtain a grinding machinability analysis report to determine a link in the part machining process that requires grinding.

3. The forward process design method for grinding of aircraft engine parts according to claim 1, characterized in that S2 include: S2.1: Part process design; S2.2: Develop component dimension inspection plan; S2.3: Use offline programming tools to compile CNC machining programs.

4. The forward process design method for grinding of aircraft engine parts according to claim 3 is characterized in that: S2.1 includes: the part process step design designs the part processing technology based on the part geometric characteristics, grinding process standards, and grinding wheel selection standards; the part process step design includes equipment selection, fixture selection, roller scheme design, and grinding wheel selection, and enables tools to select appropriate equipment, fixtures, rollers, and grinding wheels from the equipment library, tooling library, roller library, and grinding wheel library included in the resource library, and determine the roller design scheme; the part process step design also includes selecting processing parameters from the process basic database.

5. The forward process design method for grinding of aircraft engine parts according to claim 3 is characterized in that: S2.3 includes: the offline programming tool enables the tool to call the data covering boundary conditions, process programming strategies, feature processing programming strategies, processing parameters, tool parameters, processing strategies and processing plans in the process basic database, such as the structure of blades and grinders, key dimensional variables, grinding wheel parameters, roller parameters, clamping tooling, grinding posture, process data of trajectory parameters, and the equipment, fixtures, rollers, grinding wheels, and geometric features corresponding to the equipment library, tooling library, roller library, grinding wheel library, and feature model library included in the resource library to select and extract, and compile CNC machining programs.

6. The forward process design method for grinding of aircraft engine parts according to claim 1, characterized in that: In S3, the CNC machining program is simulated, and the simulation analysis includes geometric simulation and physical simulation; the geometric simulation, through the enabling tool, calls the machine tool, control system, tool model, workpiece model, blank model, and machining program required by the geometric simulation library into the geometric simulation software for collision, interference, overcutting, and undercutting analysis; the physical simulation includes machining deformation simulation and surface quality simulation; the part model is meshed, the load type is defined, the material properties are input, the boundary conditions are set, and the finite element solution is performed through the physical simulation tool to realize the physical simulation of the residual stress and temperature field of the grinding process.

7. The forward process design method for grinding of aircraft engine parts according to claim 1, characterized in that: S4 includes: actual processing according to the part process step design; selecting parts with typical characteristics and processing them through grinding machines according to the first optimized part processing technology plan, testing and evaluating the geometric accuracy and surface integrity indicators of the processed parts according to the part size detection plan, and analyzing the grinding wheel wear. According to the test and evaluation results and the comparison of the grinding wheel wear with the corresponding data in the simulation, the part processing technology plan is optimized for the second time.

8. The forward process design method for grinding of aircraft engine parts according to claim 7, characterized in that: The entire processing of S4 is monitored by a real-time monitoring system, which is electrically connected to a control system, and the control system is electrically connected to the machine tool; the real-time monitoring system monitors the processing in real time, collects process data of power, vibration, temperature and coolant flow of the processing, feeds back the process data to the control system, issues instructions to the processing equipment through the control system, and optimizes the processing in real time.

9. The forward process design method for grinding of aircraft engine parts according to claim 7, characterized in that: The inspection and evaluation includes part size inspection and evaluation, grinding surface integrity inspection and evaluation, grinding tool evaluation and grinding system evaluation; wherein, the grinding surface integrity inspection and evaluation includes surface roughness inspection, surface / subsurface damage inspection, residual stress inspection, burn and chatter mark inspection and evaluation; the grinding tool evaluation includes grinding wheel wear form evaluation and grinding wheel life evaluation; the grinding system evaluation includes spindle power, temperature and machine tool vibration evaluation.

10. The forward process design method for grinding of aircraft engine parts according to claim 7, characterized in that: The parts with typical features are blade edge plates, tenons or blade crowns.

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