Aero-engine part grinding processing positive process design method

Abstract

The present application relates to the technical field of aero-engine machining, and particularly relates to a forward process design method for aero-engine part grinding machining, which comprises the following steps: S1: grinding machining processability analysis, determining a part machining process link that needs grinding machining; S2: designing a preliminary part machining process scheme according to the part machining process link that needs grinding machining; S3: simulating and analyzing the preliminary part machining process scheme, and performing first optimization of the part machining process scheme according to the simulation analysis result; S4: performing on-site verification of the first optimized part machining process scheme, and performing second optimization of the part machining process scheme according to the comparison between the detection evaluation result after machining and the corresponding data in simulation; and S5: forming a part machining process specification from the second optimized part machining process scheme. The present application improves the grinding machining process stability and product qualification rate, reduces the trial and error cost, and reduces the dependence on the experience of operators in traditional grinding machining.

Description

Technical Field

[0001] This invention relates to the field of aero-engine machining technology, and in particular to a forward process design method for grinding aero-engine parts. Background Technology

[0002] Aero engines are considered the "crown jewel" of modern industry, and difficult-to-machine materials such as nickel-based cast superalloys are widely used in them. Due to the high quality requirements and difficulties in precision forming of irregularly shaped nickel-based cast superalloy parts for aero engines, grinding is commonly used for machining. However, current grinding processes rely heavily on human skill and experience for control. Replicating processes based on traditional experience and repeatedly performing trial grindings results in high processing costs, poor surface quality stability of machined parts, and unstable machining processes. This leads to poor reproducibility of parts meeting the same quality requirements, severely hindering the development progress of aero engine parts. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention provides a forward process design method for grinding aero-engine parts, which can improve the stability of the grinding process, reduce trial and error costs, and ensure reproducibility of parts with the same quality requirements.

[0004] To achieve the above objectives, the technical solution of the present invention is as follows:

[0005] A forward process design method for grinding aero-engine parts includes the following steps:

[0006] S1: Grinding machinability analysis to identify a specific step in the part manufacturing process that requires grinding.

[0007] S2: Based on a specific step that requires grinding, design a preliminary part processing plan;

[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 scheme, and compare the inspection and evaluation results after processing with the corresponding data in the simulation to conduct a second optimization of the part processing technology scheme;

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

[0011] Furthermore, S1 includes: using software to establish a three-dimensional model of the process, adopting the geometric features of the family parts, using manufacturability analysis software to identify the geometric features of the parts, and performing a grinding manufacturability analysis on the parts to obtain a grinding manufacturability analysis report, and determining a certain step in the part processing that requires grinding.

[0012] Furthermore, S2 includes:

[0013] S2.1: Part process design;

[0014] S2.2: Develop a plan for inspecting the dimensions of parts;

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

[0016] Furthermore, S2.1 includes: the part process design is based on the part's geometric features, grinding process standards, and grinding wheel selection standards to design the part's machining process; the part process design includes equipment selection, fixture selection, roller scheme design, and grinding wheel selection, by using the enabled tool to select appropriate equipment, fixtures, rollers, and grinding wheels from the resource library including the equipment library, tooling library, roller library, and grinding wheel library, and to determine the roller design scheme; the part process design also includes selecting machining parameters from the process foundation database.

[0017] Furthermore, S2.3 includes: The offline programming tool calls the equipment library, tooling library, roller library, grinding wheel library, and feature model library in the process base database and resource library through the enabled tool. Based on the data covering boundary conditions, process programming strategies, and feature machining programming strategies contained in the process base database, as well as 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, and the machining parameters, tool parameters, machining strategies, and machining schemes in the process base database, it selects and extracts them to establish a dimensional variable calculation model and realizes the compilation of CNC machining programs.

[0018] Furthermore, in S3, the CNC machining program is simulated. The simulation analysis includes geometric simulation and physical simulation. The geometric simulation uses the enabled tool to import 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, overcut, and undercut analysis. The physical simulation includes machining deformation simulation and surface quality simulation. The physical simulation tool is used to mesh the part model, define load types, input material properties, set boundary conditions, and perform finite element analysis to achieve physical simulation of residual stress and temperature field during grinding.

[0019] Furthermore, S4 includes: performing actual machining according to the part's machining steps design; selecting parts with typical characteristics and machining them using a grinding machine according to the first optimized part machining process scheme; evaluating the geometric accuracy and surface integrity of the machined parts according to the part size inspection scheme; analyzing the wear of the grinding wheel; and optimizing the part machining process scheme a second time based on the inspection and evaluation results and the comparison between the grinding wheel wear and the corresponding data in the simulation.

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

[0021] Furthermore, the inspection and evaluation include 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 vibration mark inspection and evaluation; the grinding tool evaluation includes grinding wheel wear pattern evaluation and grinding wheel life evaluation; the grinding system evaluation includes spindle power, temperature, and machine tool vibration evaluation.

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

[0023] The beneficial effects of this invention are:

[0024] This invention, through the aforementioned forward process design method, starts with the analysis of the machinability of grinding, simulates the design steps of the part, and then verifies and optimizes them in practice. It can be applied to the grinding of tenons / blades of blades, simulating the dimensional accuracy and surface integrity after machining. This invention supports the digital and intelligent development of grinding processes, improves the digitalization and intelligence level of grinding processes, enhances the stability of grinding processes and product qualification rates, reduces trial-and-error costs, and reduces reliance on operator experience in traditional grinding processes. Furthermore, this invention has broad market demand and application prospects for promoting the intelligent development of grinding processes for products such as gas turbines and marine propulsion systems. Using this invention can improve process consistency, reduce scrap rates, and save costs. Attached Figure Description

[0025] Figure 1 A flowchart of a forward process design method for grinding aero-engine parts according to the present invention;

[0026] Figure 2 This is a flowchart of the preliminary part processing technology scheme of the present invention. Detailed Implementation

[0027] To better explain and facilitate understanding of the present invention, the technical solution and effects of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

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

[0029] S1: Perform a grinding machinability analysis to determine a specific step in the part manufacturing process that requires grinding. The part is made of a nickel-based cast high-temperature alloy.

[0030] The process is modeled in 3D using software. Based on the process model and the structural features of the family of parts, the geometric features of the parts are identified using machinability analysis software, and a machinability analysis is performed to determine the step in the part processing that requires grinding.

[0031] Specifically, a 3D model of the process is created using UG software, and then imported into the manufacturability analysis software. The geometric features of the family of parts are also input into the manufacturability analysis software. Using these geometric features, the manufacturability analysis software identifies the geometric features of the parts and performs a grinding manufacturability analysis on the parts using the design file library, standard library, and grinding manufacturability rule library embedded in the resource library of the manufacturability analysis software. The standard library includes processing standards for parts or part materials, specifically enterprise standards, national standards, and industry standards. A grinding manufacturability analysis report is obtained, identifying a specific step in the part processing that requires grinding.

[0032] S2: Design a preliminary part processing plan based on the grinding process required;

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

[0034] S2.1: Part process design

[0035] The part machining process design is based on the part's geometric features, grinding process standards, and grinding wheel selection standards. The process design includes equipment selection, fixture selection, roller scheme design, and grinding wheel selection. By using the enabled tool, appropriate equipment, fixtures, rollers, and grinding wheels are selected from the resource library, which includes the equipment library, tooling library, roller library, and grinding wheel library, respectively, to determine the diamond roller design scheme. Reasonable machining parameters are selected from the process database, including grinding wheel linear speed, feed rate, grinding depth, grinding wheel dressing rate, dressing speed ratio, and corresponding spindle power and vibration.

[0036] S2.2: Develop a plan for inspecting the dimensions of parts;

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

[0038] Specifically, the offline programming tool calls the process base database and resource library through the enabling tool; it selects and extracts the data, process programming strategies, feature machining programming strategies, machining parameters, tool parameters, machining strategies and machining schemes in the process base database, including the structure of blades and grinding machines, key dimensional variables, grinding wheel parameters, roller parameters, clamping fixtures, grinding posture and trajectory parameters, as well as the corresponding equipment, fixtures, rollers, grinding wheels and geometric features in the resource library, including the equipment library, tooling library, roller library, grinding wheel library and feature model library, and compiles CNC machining programs to realize intelligent acquisition and transmission of process data and rapid offline grinding programming, changing the reliance on manual, work experience and single-machine manual methods.

[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. The simulation analysis includes geometric simulation and physical simulation. Through geometric and physical simulation, the feasibility of the process design scheme is determined, and the process design scheme is iteratively optimized. When it is necessary to optimize the process design scheme, the machining parameters in the process base database are corrected, and the equipment, fixtures, rollers, and grinding wheels in the resource library are selected differently.

[0041] The geometric and physical simulations, based on material properties, process parameters, geometric features, and basic material data, can simulate parts. The geometric simulation includes a geometric simulation environment; the physical simulation includes grinding deformation simulation tools and grinding thermal simulation tools.

[0042] The geometric simulation involves using an enabled tool to import the machine tools, control systems, tool models, workpiece models, blank models, machining programs, and other components required by the geometric simulation library into the geometric simulation software for analysis of collisions, interferences, overcuts, undercuts, etc.

[0043] The physical simulation includes processing deformation simulation, surface quality simulation, etc.; by using physical simulation tools to mesh the part model, define load types, input material properties, set boundary conditions, and perform finite element solutions, physical simulation of residual stress and temperature field during grinding is achieved.

[0044] S4: Conduct on-site verification of the first optimized part processing technology scheme, and compare the inspection and evaluation results after processing with the corresponding data in the simulation to conduct a second optimization of the part processing technology scheme;

[0045] Specifically, the actual machining is carried out according to the part's process design; the blade crown with typical characteristics is selected, or blade edge plates, tenons, etc. can be selected and machined by grinding machine according to the first optimized part machining process scheme. The geometric accuracy and surface integrity index of the machined part are tested and evaluated according to the part size inspection scheme, and the wear of the grinding wheel is analyzed. Based on the test and evaluation results and the grinding wheel wear, the corresponding data in the simulation are compared, and the second optimized part machining process scheme is carried out.

[0046] The evaluation includes evaluation of part dimensions, evaluation of the integrity of ground surfaces, evaluation of grinding tools, and evaluation of the grinding system. The evaluation of the integrity of ground surfaces includes surface roughness testing, surface / subsurface damage testing, residual stress testing, and evaluation of burns and vibration marks. The evaluation of grinding tools includes evaluation of grinding wheel wear patterns and grinding wheel life. The evaluation of the grinding system includes evaluation of spindle power, temperature, and machine tool vibration.

[0047] The entire machining process is monitored by a real-time monitoring system, which is electrically connected to a control system, which in turn is electrically connected to the machine tool. The real-time monitoring system monitors the machining process in real time, collecting process data such as power, vibration, temperature, and coolant flow rate. This data is then fed back to the control system, which issues commands to the machining equipment to optimize the process in real time and meet quality requirements. Simultaneously, the process data is collected and stored in a production data warehouse. Data such as grinding wheel linear speed, feed rate, 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. This database serves as a supplement to the basic process database and can be used by offline programming tools.

[0048] S5: The second optimized part machining process plan is transformed into a part machining process specification to guide the machining process.

Claims

1. An aeroengine part grinding forward process design method, characterized in that, It comprises the following steps: S1: grinding process manufacturability analysis, determining a part processing process that needs to be ground; S2: according to a part processing process that needs to be ground, design a preliminary part processing process scheme; S3: simulate and analyze the preliminary part processing process scheme, and optimize the part processing process scheme for the first time according to the simulation analysis result; S4: on-site verification of the first optimized part processing process scheme, and second optimization of the part processing process scheme according to the comparison between the detection evaluation result after processing and the corresponding data in simulation; S5: forming a part processing process scheme from the second optimized part processing process scheme; In S3, the simulation of the numerical control processing program comprises geometric simulation and physical simulation; The geometric simulation is realized by enabling tools to load the required machine tool, control system, tool model, workpiece model, blank model and processing program into the geometric simulation software for collision, interference, overcut and undercut analysis; the physical simulation comprises processing deformation simulation and surface quality simulation; the physical simulation of grinding residual stress and temperature field is realized by meshing the part model, defining the load type, inputting the material properties, setting the boundary conditions and performing finite element solution through the physical simulation tool; S4 comprises: actual processing according to the part step design; Selecting a part with typical characteristics to be processed according to the first optimized part processing process scheme through a grinding machine, detecting and evaluating the geometric precision and surface integrity index of the processed part according to the subcomponent size detection scheme, and analyzing the grinding wheel wear, and second optimization of the part processing process scheme according to the comparison between the detection evaluation result and the corresponding data in simulation.

2. The method of claim 1, wherein S1 comprises: Establishing a process three-dimensional model using software, adopting family part geometric features, identifying the part geometric features by using the manufacturability analysis software, and performing grinding process manufacturability analysis on the part to obtain a grinding process manufacturability analysis report and determine a part processing process that needs to be ground.

3. The method of claim 1, wherein S2 It comprises: S2.1: part step design; S2.2: developing a subcomponent size detection scheme; S2.3: using an offline programming tool to compile a numerical control processing program.

4. The method of claim 3, wherein, S2.1 comprises: the part step design is designed according to the part geometric features, grinding process standards and grinding wheel selection standards; the part step design comprises equipment selection, fixture selection, roller scheme design and grinding wheel selection, appropriate equipment, fixtures, rollers and grinding wheels are selected from the equipment library, tooling library, roller library and grinding wheel library in the resource library through enabling tools, and the roller design scheme is determined; the part step design further comprises selecting processing parameters from the process database.

5. The method of claim 3, wherein, S2.3 comprises: the off-line programming tool selects and extracts the corresponding equipment, fixture, roller, grinding wheel, geometric feature of the equipment library, fixture library, roller library, grinding wheel library, feature model library included in the process database through enabling tool calls to the data covering boundary conditions included in the process database, process programming strategy, feature processing programming strategy, processing parameters in the process database, tool parameters, processing strategy, processing scheme, grinding wheel parameters, roller parameters, clamping tooling, grinding posture, trajectory parameters, and selects and extracts the corresponding equipment, fixture, roller, grinding wheel, geometric feature of the equipment library, fixture library, roller library, grinding wheel library, feature model library included in the resource library.

6. The method of claim 1, wherein, The whole machining process of S4 is monitored by a real-time monitoring system, the real-time monitoring system is electrically connected with a control system, the control system is electrically connected with the machine tool; the real-time monitoring system monitors the machining process in real time, collects the power, vibration, temperature and cooling liquid flow process data of the machining process, feeds back the process data to the control system, and issues instructions to the machining equipment through the control system to optimize the machining process in real time.

7. The method of claim 1, wherein, The detection and evaluation includes part size detection and evaluation, grinding processing surface integrity detection and evaluation, grinding tool evaluation and grinding processing system evaluation; wherein the grinding processing surface integrity detection and evaluation includes surface roughness detection, surface / subsurface damage detection, residual stress detection, burn and chatter mark detection and evaluation; the grinding tool evaluation includes grinding wheel wear form evaluation and grinding wheel life evaluation; the grinding processing system evaluation includes spindle power, temperature and machine tool vibration evaluation.

8. The method of claim 1, wherein, The typical feature part is a blade rim, a tenon tooth or a blade crown.

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