A method of machining a four-stage to nine-stage disk assembly

Abstract

The application discloses a machining method of a four-stage disc to nine-stage disc assembly, and comprises the following steps: installing a clamping tool on a five-axis machining center platform; fixing the four-stage disc to nine-stage disc assembly with the front end surface downward on the positioning ring of the clamping tool, and then finding the center with the barrel auxiliary reference; respectively adopting grinding and turning methods to process the end surface and the stop port of the four-stage disc to nine-stage disc assembly under the same reference; and checking the full runout, flatness, parallelism, coloring mark area, perpendicularity, roundness and concentricity of the machining position of the four-stage disc to nine-stage disc assembly to meet the requirements. The application clamps the four-stage disc to nine-stage disc assembly in the five-axis machining center through the design of a clamping tool, and then finds the center of the barrel through the tool centering and tilt screw, so that the end surface and the stop port of the four-stage disc to nine-stage disc assembly are machined under the same reference, the shape and position relationship after machining is ensured, and the machining quality is improved.

Description

Technical Field

[0001] This invention belongs to the technical field of high-pressure compressor rotor processing methods, specifically relating to a processing method for a four-stage to nine-stage disk assembly. Background Technology

[0002] The fourth to ninth stage disc assembly is a crucial component of the high-pressure compressor rotor, providing rigid connections. Under operating conditions, this assembly withstands extreme centrifugal loads, torque transmission, and impact loads in a complex flow field environment. After long-term service, harsh environments and overloaded maneuvers induce stress creep deformation and high-frequency fretting wear at the drum connection stops. This can easily lead to poor shape and position consistency, morphological distortion, and non-standard fit issues at the front and rear stops and their auxiliary sections of the fourth to ninth stage disc assemblies. These directly affect the assembly runout characteristics and initial imbalance, impacting the core engine assembly quality and overall engine performance during testing.

[0003] Statistics show that 100% of the front stop and rear flange mounting faces of the fourth to ninth grade disc assemblies are warped and require grinding repair, while about 70% of the stops require machining repair due to dimensional deviations or poor form and position. The existing repair and processing methods for fourth to ninth grade disc assemblies are as follows: the end faces are manually ground to ensure flatness, and the stops are machined to ensure concentricity.

[0004] However, existing repair and processing methods have the following problems:

[0005] 1. The end face and the stop are machined separately, and their datums are inconsistent, resulting in poor perpendicularity between the machined end face and the stop. Repairing the parallelism of the end face requires extremely high skill from personnel, and the process cannot be effectively controlled. Poor shape and position of components leads to poor concentricity after rotor assembly, which can easily induce engine vibration failure.

[0006] 2. The separate processing method of machining and grinding to repair the stop is inefficient. Each grinding operation takes 16 hours and each stop repair takes 4 hours. Moreover, the high-intensity grinding work causes significant damage to the human body. Summary of the Invention

[0007] In order to solve the problems of poor consistency between the form and position of the end face and the stop produced by existing methods and the time-consuming nature of conventional repair methods, this invention proposes a processing method for four-level to nine-level disc assemblies.

[0008] The objective of this invention is achieved through the following technical solution:

[0009] This invention discloses a method for processing assemblies of four- to nine-level disks, comprising the following steps:

[0010] The clamping fixture is installed on a five-axis machining center platform. The clamping fixture includes a base assembly, an adapter cylinder fixed on the base assembly, a positioning ring fixed on the adapter cylinder, a pressure plate for pressing the fourth-level disc of the fourth-to-ninth-level disc assembly onto the positioning ring, a cover plate for pressing onto the ninth-level disc of the fourth-to-ninth-level disc assembly, a screw for connecting the cover plate and the positioning ring, and a connecting rod for connecting the pressure plate and the cover plate.

[0011] Fix the fourth to ninth stage disc assembly with the front end facing down on the positioning ring of the clamping fixture, and then align it using the cylinder body as an auxiliary reference.

[0012] The end faces and stops of the fourth to ninth level disc assemblies are machined under the same datum by grinding and turning methods respectively.

[0013] Inspect the runout, flatness, parallelism, area of ​​color marks, perpendicularity, roundness and concentricity of the machining positions of the fourth to ninth level disc assembly to ensure they meet the requirements.

[0014] The beneficial effects of this invention are:

[0015] 1. This invention designs a clamping fixture to clamp the fourth to ninth level disc assembly in a five-axis machining center. Simultaneously, by using the fixture's self-aligning and tilting screws to align the cylinder, the end faces and stops of the fourth to ninth level disc assembly can be machined under the same reference, ensuring the form and position relationship after machining and improving the machining quality.

[0016] 2. This invention uses a five-axis machining center platform to simultaneously automate the machining of the end face and the stop, reducing manpower consumption and improving machining efficiency. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the structure of the clamping tooling of the present invention after being assembled with the fourth to ninth level disk assembly;

[0019] Figure 2 for Figure 1 AA attempt. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0021] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0022] It should be noted that, unless otherwise specified, the embodiments and features described in this invention can be combined with each other.

[0023] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0024] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use, or the orientation or positional relationship commonly understood by those skilled in the art. They are only used for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. In addition, the terms "first," "second," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0025] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0026] The first aspect of this invention discloses a method for processing a four-level to nine-level disk assembly, comprising steps S11 to S14. It should be noted that the step identifiers in this solution are merely for illustrative purposes and do not constitute a limitation on the order of steps. The order of each step is determined by its verbal description and the sequential connection of each signal.

[0027] Step S11: Install the clamping fixture on the five-axis machining center platform. The clamping fixture includes a base assembly, an adapter cylinder 11 fixed on the base assembly, a positioning ring 12 fixed on the adapter cylinder, a pressure plate 13 for pressing the fourth-level disc of the fourth-level to ninth-level disc assembly onto the positioning ring, a cover plate 14 for pressing onto the ninth-level disc of the fourth-level to ninth-level disc assembly, a screw 17 for connecting the cover plate and the positioning ring, and a connecting rod 15 for connecting the pressure plate and the cover plate.

[0028] Specifically, the structure of the clamping fixture is as follows: Figure 1 , 2 As shown.

[0029] The inventors developed this clamping fixture, which can fix the fourth- to ninth-level disc assembly 2 on a five-axis machining center platform to achieve end face and stop machining. The clamping fixture is designed based on the product's structural dimensions, the machining center's compatible dimensions, clamping requirements, and the structural characteristics of the machined position.

[0030] The outer diameter of the positioning ring 12 is compatible with the inner diameter of the fourth-level disk.

[0031] Specifically, in order to facilitate the adjustment of the horizontal state of the fourth to ninth level disc assembly and improve the processing quality, the base assembly includes a base 161, an adapter plate 162 placed on the base 161, a support 163 set on the base 161, a first adjusting bolt 164 set on the adapter plate 162 and placed around the adapter cylinder for adjusting the horizontal state of the adapter plate 162, and a second adjusting bolt 165 set on the support 163 for controlling the locking state of the adapter plate 162.

[0032] Furthermore, a hanging ring 166 is provided on the base 161.

[0033] Step S12: After fixing the front end face of the fourth- to ninth-level disc assembly onto the positioning ring of the clamping fixture, align the cylinder body of the fourth- to ninth-level disc assembly.

[0034] Specifically, first place the fourth to ninth stage disc assembly with the front end facing down on the positioning ring of the clamping fixture, and use fixing screws and cover plates to clamp and fix the fourth to ninth stage disc assembly; then adjust the radial and axial adjusting screws, and use a digital dial indicator to level and align the cylinder.

[0035] Step S13: Use a five-axis machining center to simultaneously machine the end faces and stops of the fourth to ninth level disc assemblies.

[0036] Specifically, the machining dimensions of the fourth to ninth level disk assemblies are shown in Table 1 below.

[0037] Table 1

[0038]

[0039] To address this, the front faces of the fourth to ninth level disc assemblies were ground. During grinding, the rotary table speed of the five-axis machining center was 2 rpm, the grinding head diameter was Φ30mm, the spindle speed was 9000 rpm, the spindle feed rate was 0.002 mm / min, and the tool path was as follows: the probe moved to the center position of the rotary table, and the x-coordinate X0 of the point with the largest circumferential dimension of the stop was measured. 3 and the ordinate Z0 of the point with the maximum axial dimension on the lower end face. 3 Set the starting point for machining; the feed speed of the grinding head is 2000 mm / min, and the grinding head is moved to 10 mm directly below the end face; the feed speed is controlled at 10 mm / min, and the grinding head is ground upwards by 0.02 mm; the feed speed is controlled at 0.002 mm / min, and the grinding head is ground upwards by 0.002 mm; the retraction speed is controlled at 200 mm / min, and the tool is retracted to 30 mm below the Z-axis; the retraction speed is controlled at 2000 mm / min, and the tool is retracted to 20 mm on the X-axis and 100 mm on the Z-axis.

[0040] The rear end face of the assemblies from level four to level nine is ground. During grinding, the rotary table speed of the five-axis machining center is 2 rpm, the grinding head diameter is Φ30mm, the spindle speed is 9000 rpm, the spindle feed rate is 0.002 mm / min, and the tool path is as follows: the probe moves to the center position of the rotary table, and the x-coordinate X0 of the point with the largest circumferential dimension of the stop is measured. 4 and the ordinate Z0 of the point with the maximum axial dimension on the upper end face. 4 Set the starting point for machining; the feed speed of the grinding head is 2000 mm / min, and the grinding head is moved to 10 mm directly above the end face; the feed speed is controlled at 10 mm / min, and the grinding head is ground downwards by 0.02 mm; the feed speed is controlled at 0.002 mm / min, and the grinding head is ground downwards by 0.002 mm; the retraction speed is controlled at 200 mm / min, and the tool is retracted to 30 mm above the Z-axis; the retraction speed is controlled at 2000 mm / min, and the tool is retracted to 20 mm on the X-axis and 100 mm on the Z-axis.

[0041] The front stop of the assemblies from level 4 to level 9 discs is machined. The final machining dimensions of the front stop are set. During machining, the rotary table speed of the five-axis machining center is 16 rpm, the spindle feed rate is 1 mm / min, and the tool path is as follows: the probe moves to the center of the rotary table, and the x-coordinate X0 of the point with the maximum circumferential dimension of the stop is measured. 1 and the ordinate Z0 of the point with the maximum axial dimension on the lower end face. 1 Set the starting point for machining; use a feed rate of 200 mm / min to feed the tool along the Z-axis to 10 mm below the starting point; control the feed rate to 20 mm / min and feed along the Z-axis to 1 mm below the starting point; control the feed rate to 1 mm / min and perform upward turning; control the retraction rate to 20 mm / min and retract the tool 20 mm along the X-axis; control the retraction rate to 200 mm / min and retract the tool 100 mm along the Z-axis.

[0042] The rear stop of the assemblies from level 4 to level 9 discs is machined. The final machining dimensions of the rear stop are set. During machining, the rotary table speed of the five-axis machining center is 16 rpm, the spindle feed rate is 1 mm / min, and the tool path is as follows: the probe moves to the center of the rotary table, and the x-coordinate X0 of the point with the maximum circumference of the stop is measured. 2 and the ordinate Z0 of the point with the maximum axial dimension on the upper end face. 2 Set the starting point for machining; use a feed rate of 200 mm / min to feed the tool along the Z-axis to 10 mm above the starting point; control the feed rate to 20 mm / min and feed along the Z-axis to 1 mm above the starting point; control the feed rate to 1 mm / min and perform downward turning; control the retraction rate to 20 mm / min and retract the tool 20 mm along the X-axis; control the retraction rate to 200 mm / min and retract the tool 100 mm along the Z-axis.

[0043] In this step, the machining parameters of the five-axis machining center platform are crucial to the machining quality of the end faces and stops of the fourth to ninth level disc assemblies. Based on the final surface roughness requirement of Ra 0.80 μm, process experiments are conducted to determine the corresponding spindle speed, feed rate, and tool path for stop turning, as well as the grinding head material and the corresponding spindle speed, feed rate, and grinding head path for end face grinding. The fourth to ninth level disc assemblies are fixed using cover plates and screws. After adjusting the radial and axial adjusting screws and using a dial indicator to align the cylinder shape, the end faces and stops of the fourth to ninth level disc assemblies are machined simultaneously to ensure optimal relative positioning with the cylinder after machining and repositioning.

[0044] Step S14: Check the runout, flatness, parallelism, color mark area, perpendicularity, roundness and concentricity of the machining positions of the fourth to ninth level disk assemblies until they meet the requirements.

[0045] Specifically, a dial indicator is used to measure the relative runout between the machining position and the cylinder. The machining position includes the end face and stop of the fourth to ninth level disc assembly to ensure that all axes of the parts are consistent.

[0046] For flat surface coloring mark inspection, measure the coloring area. If the coloring area is greater than or equal to 80% and there is no interruption along the circumference, the flatness of the coloring is determined to meet the processing requirements.

[0047] The roundness tester measures the form and position characteristics of the end faces and stops of the fourth to ninth level disc assemblies after machining. It measures flatness, parallelism, roundness, concentricity, and perpendicularity. When flatness is less than or equal to 0.005mm, parallelism is less than or equal to 0.01mm, roundness is less than or equal to 0.01mm, concentricity is less than or equal to 0.01mm, and perpendicularity is less than or equal to 0.01mm, the machining of the fourth to ninth level disc assemblies is deemed to meet the requirements.

[0048] After processing, the surface roughness was checked and compared with a roughness template. The surface roughness Ra is not less than 0.80 μm, which meets the technical requirements.

[0049] This solution uses clamping fixtures to fix the fourth to ninth level disc assemblies onto a five-axis machining center platform, enabling the machining of the end faces and stops. This ensures that the end faces and stops are within the range of deviation from the cylinder axis, as well as their perpendicularity and parallelism. After machining, the parallelism can be controlled to below 0.01mm, the perpendicularity to below 0.01mm, and the concentricity of the stops to the cylinder to below 0.01mm. The first-pass yield is increased to 100%, significantly reducing rework, lowering production costs, and improving enterprise efficiency.

[0050] Those skilled in the art will recognize that the embodiments described herein are intended to help the reader understand the principles of the invention, and should be understood that the scope of protection of the invention is not limited to such specific statements and embodiments. Those skilled in the art can make various other specific modifications and combinations based on the technical teachings disclosed in this invention without departing from the spirit of the invention, and these modifications and combinations are still within the scope of protection of this invention.

Claims

1. A method for processing a four- to nine-level disk assembly, characterized in that, Includes the following steps: The clamping fixture is installed on a five-axis machining center platform. The clamping fixture includes a base assembly, an adapter cylinder fixed on the base assembly, a positioning ring fixed on the adapter cylinder, a pressure plate for pressing the fourth-level disc of the fourth-to-ninth-level disc assembly onto the positioning ring, a cover plate for pressing onto the ninth-level disc of the fourth-to-ninth-level disc assembly, a screw for connecting the cover plate and the positioning ring, and a connecting rod for connecting the pressure plate and the cover plate. Fix the fourth to ninth stage disc assembly with the front end facing down on the positioning ring of the clamping fixture, and then align it using the cylinder body auxiliary reference. The end faces and stops of the fourth to ninth level disc assemblies are machined under the same datum by grinding and turning methods respectively. Inspect the runout, flatness, parallelism, area of ​​color marks, perpendicularity, roundness and concentricity of the machining positions of the fourth to ninth level disc assembly to ensure they meet the requirements; The end faces and stops of the fourth to ninth level disc assemblies are machined using a five-axis machining center, including: The front stop is machined, and the final machining dimensions of the front stop are set. During machining, the rotary table speed of the five-axis machining center is 16 rpm, the spindle feed rate is 1 mm / min, and the tool path is as follows: the probe moves to the center position of the rotary table, and the x-coordinate X0 of the point with the maximum circumference of the stop is measured. 1 and the ordinate Z0 of the point with the maximum axial dimension on the lower end face. 1 Set the starting point for machining; use a feed rate of 200 mm / min to feed along the Z-axis to 10 mm below the starting point; control the feed rate at 20 mm / min to feed along the Z-axis to 1 mm below the starting point; control the feed rate at 1 mm / min to perform upward turning; control the retraction rate at 20 mm / min to retract 20 mm along the X-axis; control the retraction rate at 200 mm / min to retract 100 mm along the Z-axis. The rear stop is machined, and the final machining dimensions of the rear stop are set. During machining, the rotary table speed of the five-axis machining center is 16 rpm, the spindle feed rate is 1 mm / min, and the tool path is as follows: the probe moves to the center position of the rotary table, and the x-coordinate X0 of the point with the maximum circumference of the stop is measured. 2 and the ordinate Z0 of the point with the maximum axial dimension on the upper end face. 2 The feed rate is set to 200 mm / min, and the tool feeds along the Z-axis to 10 mm above the machining start point; the feed rate is controlled at 20 mm / min, and the tool feeds along the Z-axis to 1 mm above the machining start point; the feed rate is controlled at 1 mm / min, and the tool moves downwards for 10 mm; the retraction rate is controlled at 20 mm / min, and the tool retracts along the X-axis for 20 mm; the retraction rate is controlled at 200 mm / min, and the tool retracts along the Z-axis for 100 mm. The end faces and stops of the fourth to ninth level disc assemblies are machined using a five-axis machining center, including: The front face is ground. During grinding, the rotary table speed of the five-axis machining center is 2 rpm, the grinding head diameter is Φ30mm, the spindle speed is 9000 rpm, the spindle feed rate is 0.002 mm / min, and the tool path is as follows: the probe moves to the center position of the rotary table, and the x-coordinate X0 of the point with the largest circumferential dimension of the stop is measured. 3 and the ordinate Z0 of the point with the maximum axial dimension on the lower end face. 3 Set the starting point for machining; set the grinding head feed speed to 2000 mm / min and move the grinding head to 10 mm directly below the end face; control the feed speed to 10 mm / min and grind upwards by 0.02 mm; control the feed speed to 0.002 mm / min and grind upwards by 0.002 mm; control the retraction speed to 200 mm / min and retract the tool to 30 mm below the Z-axis; control the retraction speed to 2000 mm / min and retract the tool to 20 mm on the X-axis and 100 mm on the Z-axis. The rear end face is ground. During grinding, the rotary table speed of the five-axis machining center is 2 rpm, the grinding head diameter is Φ30mm, the spindle speed is 9000 rpm, the spindle feed rate is 0.002 mm / min, and the tool path is as follows: the probe moves to the center position of the rotary table, and the x-coordinate X0 of the point with the largest circumferential dimension of the stop is measured. 4 and the ordinate Z0 of the point with the maximum axial dimension on the upper end face. 4 Set the starting point for machining; the feed speed of the grinding head is 2000 mm / min, and the grinding head is moved to 10 mm directly above the end face; the feed speed is controlled at 10 mm / min, and the grinding head is ground downwards by 0.02 mm; the feed speed is controlled at 0.002 mm / min, and the grinding head is ground downwards by 0.002 mm; the retraction speed is controlled at 200 mm / min, and the tool is retracted to 30 mm above the Z-axis; the retraction speed is controlled at 2000 mm / min, and the tool is retracted to 20 mm on the X-axis and 100 mm on the Z-axis.

2. The method for processing a four- to nine-level disk assembly according to claim 1, characterized in that, The inspection of the relative runout of the machining positions of the fourth to ninth level disk assemblies, the inspection of planar color imprints, and the concentricity and parallelism to meet the requirements includes: The relative runout between the machining position and the cylinder was measured using a dial indicator, ensuring that the axes of all parts in the fourth to ninth level disc assembly were aligned. A flatness coloring mark inspection was conducted; the colored area was greater than or equal to 80%, with no breaks along the circumference, indicating that the flatness coloring met the machining requirements. A roundness tester was used to measure the shape and position characteristics of the end faces and stops of the fourth to ninth level disc assemblies after machining, measuring flatness, parallelism, roundness, concentricity, and perpendicularity. When flatness was less than or equal to 0.005 mm, parallelism less than or equal to 0.01 mm, roundness less than or equal to 0.01 mm, concentricity less than or equal to 0.01 mm, and perpendicularity less than or equal to 0.01 mm, the machining of the fourth to ninth level disc assemblies was deemed to meet the requirements. A surface roughness inspection was performed after machining, using a roughness template for comparison; the surface roughness Ra≯0.80μm met the technical requirements.

3. The method for processing a four- to nine-level disk assembly according to claim 1, characterized in that, The base assembly includes a base (161), an adapter plate (162) placed on the base (161), a support (163) disposed on the base (161), a first adjusting bolt (164) disposed on the adapter plate (162) and placed around the adapter cylinder for adjusting the horizontal state of the adapter plate (162), and a second adjusting bolt (165) disposed on the support (163) for controlling the locking state of the adapter plate (162).

4. The method for processing a four- to nine-level disk assembly according to claim 3, characterized in that, A lifting ring (166) is provided on the base (161).

Images