Closed component integrated cathode in-situ continuous full-profile electrolytic machining device and method

Abstract

The invention relates to a closed component integrated cathode in-situ continuous full-profile electrolytic machining device and method, and belongs to the field of electrolytic machining. The method is characterized in that the integrated cathode is composed of an end face cathode, a blade basin cathode, a blade back cathode, a hub cathode, a blade crown cathode and an insulating supporting base body, and all the cathodes are fixed to the insulating base body, insulated from one another and independently lead electricity. The integrated cathode is of a hollow structure, and internal flushing liquid processing can be achieved. The power-on / power-off direction of each cathode is matched with the feeding direction, that is, when each cathode is fed in the normal direction of the molded surface of the cathode, the cathode is powered on, the corresponding molded surface of the workpiece is subjected to electrochemical dissolution, and other cathodes are powered off and serve as insulating materials, so that full-molded-surface electrolytic machining of the closed component can be sequentially and continuously completed in situ. The integrated cathode is adopted, full-profile in-situ continuous electrolytic machining of the closed component can be achieved through one-time clamping, multiple sets of cathodes and clamps do not need to be designed, and the machining efficiency and the machining quality are improved.

Description

Technical Field

[0001] The invention belongs to the technical field of electrolytic machining, and in particular relates to a closed component integrated cathode in-situ continuous full-surface electrolytic machining device and method. Background Art

[0002] Closed components made of high-temperature alloys and titanium alloys are one of the core parts of high-performance turbojet engines and launch vehicle engine turbopumps. Closed components usually include hubs, blade crowns and blades. Thanks to the integral design with blade crowns, closed components can greatly reduce the gas escape loss between the blade tip and the blade crown, improve aerodynamic efficiency, and at the same time, because the hub, blades and blade crowns are designed as an integral frame structure, the connection between the parts is reduced, making the structure more compact, while reducing the weight of the parts, the strength and rigidity of the impeller are enhanced, and the reliability and service life of the parts are significantly improved.

[0003] From the blank to the final ideal shape, the closed component needs to form four surfaces, including the blade basin surface, blade back surface, hub surface and blade crown surface. Due to the existence of the blade crown, the blade channel is only open at the inlet and exhaust sides, and the blade is bent and twisted, which greatly reduces its openness. Therefore, the tool movement is restricted during traditional cutting, and it is very easy to interfere with the surface to be processed, resulting in poor processing accessibility. In addition, the cutting performance of the above materials is poor, so the processing difficulty is relatively high. At present, the main processing methods for closed components are CNC milling, electric spark machining, arc discharge machining and electrolytic machining. CNC milling has the advantages of high degree of automation, short preparation cycle and high processing accuracy, but it has large tool loss, low processing efficiency, and easy deformation of thin-walled parts. For blades with compound bending and twisting, its processing accessibility is poor. EDM has the characteristics of wide material adaptability, high machining accuracy, no macro-cutting force during machining, and low surface roughness machining. It is particularly suitable for machining difficult-to-machine materials and thin-walled integral components. However, the tool electrode has loss, which affects the electrode's repeated machining accuracy. The recast layer and micro-cracks produced by EDM will affect the surface quality of the machined workpiece. Arc discharge machining has high efficiency and low cost, but the electrode loss is large, the material is easily ablated, and a thicker heat-affected layer is produced on the machined surface.

[0004] Electrolytic machining is a process method based on the principle of electrochemical anodic dissolution to shape the anodic workpiece into a certain shape and size. It has the characteristics of high material removal rate, good machining surface quality, no tool cathode loss, and a wide machining range. It can be used to process any conductive material and is not limited by the mechanical properties of the material such as hardness, strength, and toughness. It is often used to process various difficult-to-cut metals such as nickel-based high-temperature alloys, titanium alloys, and intermetallic compounds. It is particularly suitable for mass production of parts and the processing of various parts with complex three-dimensional surfaces. It has been widely used in aerospace, weapons and other industries, and has become one of the mainstream manufacturing methods for difficult-to-process materials and complex-shaped workpieces in domestic and foreign aero-engines.

[0005] For open integral blades, the traditional electrolytic machining method is generally divided into two processes: blade channel pre-machining and blade profile finishing. First, through the blade channel pre-machining process, most of the material between adjacent blades is etched away to form a channel, and a certain machining allowance is reserved on the blade blank. In the blade profile finishing process, the forming cathode moves into the blade channel, and the allowance reserved in the previous process is removed by feeding the forming cathode to form the final blade contour and complete the blade profile finishing. If the traditional electrolytic machining method is used to process closed components, in addition to the blade channel pre-machining process, in the blade profile finishing process, it is necessary to design the hub surface machining cathode, the blade crown surface machining cathode, the blade basin surface machining cathode and the blade back surface machining cathode and their corresponding fixtures separately, and at the same time add the cathode correction test. The process is cumbersome and greatly reduces the processing efficiency. The repeated positioning error caused by replacing the cathode and fixture in each process will greatly reduce the processing accuracy. Therefore, the traditional integral blade step-by-step electrolytic machining method is difficult to meet the requirements of mass production, and it is urgent to explore new low-cost, high-efficiency and high-precision electrolytic machining process methods.

[0006] In the patent "A non-circular tool milling device suitable for machining closed complex curved surfaces" (application number 201710739181.3 applicant Beijing University of Aeronautics and Astronautics Zaozhuang Beihang Machine Tool Innovation Research Institute Co., Ltd. inventor Chen Zhitong Yang Jianshi Quanfang Zhang Yuningtao Li Shanshan Qu Chuanrui Tianye), a non-circular tool milling device is used for machining closed impellers, impeller rings, and casing flow channels, which can improve the machining efficiency and quality of curved surfaces and is suitable for machining curved surfaces in semi-enclosed spaces. In contrast, this patent uses electrolytic machining, which has no tool electrode loss, can process difficult-to-machine materials, and can also process complex curved and twisted surfaces with poor openness.

[0007] In the patent "Five-axis plunging milling method for closed integral blade disk" (application number 200910219433.5 applicant Northwestern Polytechnical University inventor Yao Changfeng Ren Junxue Zhang Dinghua Shi Yaoyao Tian Rongxin Liang Yongshou Huang Xinchun), the processing area of ​​the channel of the closed integral blade disk is divided, and the plunging milling tool position trajectory of the intake side processing area and the exhaust side processing area is obtained respectively, and the closed integral blade disk is plunging milled. In comparison, this patent adopts electrolytic machining, which has high machining efficiency and short machining cycle, and is suitable for machining complex curved surfaces of bending and twisting composite blades with insufficient openness.

[0008] In the patent "Blade EDM Processing Method for Integrally Closed Blade Ring and Its Fixture and Electrode" (application number 201811059341.0 applicant Xi'an Xihang Group Wright Aviation Manufacturing Technology Co., Ltd. inventor Shi Hongmin Li Changqing Song Xiaoqing Peng Mingyou Zhang Yonggang Shi Junqiang Feng Yong Zheng Xiaosong), a blade EDM processing method for integrally closed blade ring and its fixture and electrode are proposed. The blade and airflow channel profiles are guaranteed by the electrode profile. This method is not limited by the complexity of the blade profile. By using the forming electrode and cooperating with the electrode fixture, multi-axis linkage EDM processing can be realized on the EDM forming machine. In contrast, this patent adopts in-situ continuous full-surface electrolytic processing, which does not require the replacement of fixtures and repositioning, has a simple process and high repetitive processing accuracy.

[0009] In the patent "Closed integral blade disk EDM pre-hole extraction and chip removal method" (application number 201810899563.7 applicant Shanghai Jiao Tong University Shenzhen Research Institute Shanghai Jiao Tong University inventor Kang Xiaoming Zhao Wansheng Xu Haihua), a pre-hole for extraction is machined on the closed integral blade disk blank, and then the blade channel is machined by multi-axis linkage EDM, which can effectively remove the discharge erosion products and improve the processing efficiency. In contrast, this patent adopts electrolytic machining without pre-treatment of the workpiece, and can achieve integrated rough and fine machining of closed components in one machining process.

[0010] In the patent "Laminated internal liquid forming electrode for high-speed electrical discharge machining" (application number 201210026722.5 applicant Shanghai Jiaotong University inventor Zhao Wansheng Gu Lin Xiang Xiaoli), a laminated internal liquid forming electrode for high-speed electrical discharge machining is proposed, including an electrode laminate group and an electrode joint, wherein the electrode laminate group is formed by stacking and fastening a plurality of electrode sheets to form a forming electrode for electrical discharge machining, and a plurality of through grooves are provided on the surface of the electrode sheet, and a plurality of through holes are constructed between the forming electrodes by stacking the electrode sheets, which are used for internal liquid flushing to realize the pre-processing of the blade channel. In comparison, this patent adopts an integrated cathode partition power-on mode, and the cathode power on / off is matched with the feed direction, which can realize localized dissolution, high processing accuracy, and no cathode loss, and can perform in-situ continuous full-surface finishing, with high processing efficiency. The hollow cathode structure inside can realize internal liquid flushing, improve the uniformity of the flow field and processing stability.

[0011] In the patent "A method for electrolytic machining of an integral blade disk" (application number 201811128151.X applicant China Aviation Manufacturing Technology Research Institute inventors Huang Mingtao Zhang Mingqi Cheng Xiaoyuan Fu Junying), the machining head of the machining tool used includes the blade basin profile and the blade back profile, completing the fine machining of the blade channel and blade profile of the open blade disk. In comparison, this patent uses an integrated cathode, which can achieve internal flushing, with better flow field uniformity. The power-on state of the cathode for machining each profile and the cathode feed direction match, so that the entire profile of the closed component is finally dissolved in the normal direction, improving the machining accuracy.

[0012] In the patent "Double-sided combined double cathode and segmented power control integral blade disk electrolytic processing method" (application number 202210306217.X applicant Nanjing University of Aeronautics and Astronautics inventor Xu Zhengyang Shen Zhenyu Liu Jia Zhu Dong), a double-sided combined double-tool cathode is used for simultaneous feeding to perform step-by-step electrolytic processing of the blade channel and blade basin and blade back surfaces of the open integral blade disk. In comparison, this patent uses an integrated cathode with good cathode rigidity, which can realize full-surface electrolytic processing of closed blade disks with complex twisted surfaces. The cathode is hollow inside, which can realize internal flushing to ensure flow field uniformity and processing stability.

[0013] In the patent "Device and method for electrolytic machining of closed blade ring screw-in blade channel" (application number 202310111384.3, applicant Nanjing University of Aeronautics and Astronautics, inventor Zhu Dong, Yang Tuo, Zuo Hang, Zhu Di), a device and method for electrolytic machining of closed blade ring screw-in blade channel is proposed. During machining, the cathode remains fixed, the workpiece is rotated and fed along the axial arc trajectory of the blade, and electrolytic machining is performed on the cathode end surface to gradually shape the blade channel. A group slit structure is provided on the cathode head to ensure that the electrolyte is fully supplied to the machining area. In comparison, this patent uses an integrated cathode, which can complete the entire cycle of coarse and fine integrated machining with one clamping, thereby improving machining efficiency. At the same time, each cathode is independently energized, and the electric field in the machining area is discrete. The cathodes for machining each profile are all fed in the normal direction, realizing normal and localized dissolution of the workpiece surface, improving machining accuracy while avoiding stray corrosion, and effectively improving the machining surface quality.

[0014] In the patent "Combined electrode processing method for improving the efficiency of EDM machining of turbine disks with blade crowns" (application number 201410195975.4 applicant Capital Aerospace Machinery Company China Academy of Launch Vehicle Technology inventor Chen Jilun Zhong Xiaohong Zhang Kun Ma Ning Sun Xiujing Zhang Wangang Shen Yan Zhu Pingping), a combined electrode processing method for improving the efficiency of EDM machining of turbine disks with blade crowns is proposed, including rough machining, semi-finishing and finishing processes, using multiple combined electrodes for rough machining, increasing the discharge area, and improving the overall efficiency of the machining process by about 30%, and then replacing the semi-finishing and finishing electrodes for machining, shortening the electrode replacement time and improving the machine tool utilization rate. In comparison, this patent uses an integrated cathode with a simple cathode structure, reducing the cathode cost, simplifying the production process, and eliminating the need for multiple clamping and positioning, which can effectively improve the machining accuracy.

[0015] In the patent "A multi-channel parallel machining electrode for rough machining of closed integral blade disks" (application number 202011389263.8 applicant Harbin Institute of Technology inventors Chi Guanxin Jia Yuchao Wang Zhenlong Cui Lijuan Wang Yukui), a multi-channel parallel machining electrode composed of an electrode base and an electrode head is used to generate arc pulse discharge to rough-machine the closed component, and then fine-machine it using processes such as electric spark machining. In comparison, this patent uses a set of fixtures and an integrated cathode to achieve in-situ continuous full-surface machining, which improves machining efficiency.

[0016] In the patent "High-precision closed blade disk forming method" (application number 201210588218.4 applicant Chinese People's Liberation Army General Staff 60th Institute inventor Wu Gaoqiang Shi Xiaohong Ding Lei Zhuang Zhenyu Cui Wei), the closed integral blade disk is split into two parts, cut and processed separately, and finally welded into a whole, and then finely processed into a finished product. In comparison, this patent realizes the full-surface processing of the integral component on a blank, avoiding the introduction of defects caused by other connection methods, and can improve the stability and life of the workpiece.

[0017] In the patent "Device and method for electrolytic processing of closed components" (application number 202211135473.3 applicant Nanjing University of Aeronautics and Astronautics inventor Zhu Dong Hou Zhenhao Ren Mingzhu Zhu Di), a device and method for electrolytic processing of closed components are proposed. The device designs the cathode and the fixture as a whole, and performs fine processing on the blade profile of the closed component. The integrated fixture allows the fixture and the cathode to move together, which can not only realize the joint processing of the internal and external flow channels of the closed component and the blade profile, but also form a closed flow field in the processing area to improve the uniformity and stability of the flow field. In comparison, this patent uses an integrated cathode, which can realize in-situ continuous electrolytic processing of the entire surface of the cascade channel and the blade profile, avoiding step-by-step electrolysis, reducing the process, and improving the processing efficiency.

[0018] In the electrolytic machining process of closed components, from the blank to the ideal surface, most of the current research needs to be divided into two processing steps, that is, the use of two independent processes of blade channel pre-machining and blade surface finishing. There are few studies that complete the rough and fine integrated electrolytic machining of closed component blanks in one cycle. This leads to the need to design and process cathodes and fixtures separately for different processing steps, and disassemble and clamp fixtures on different electrolytic machining machines for separate processing, resulting in low processing efficiency, long processing cycle, and reduced processing accuracy. Therefore, in order to simplify the cathode design, improve processing efficiency, shorten the processing cycle, reduce clamping positioning errors, ensure processing accuracy, reduce stray corrosion, and improve the quality of the processed surface, the inventor provides a method for in-situ continuous full-surface electrolytic machining of closed component integrated cathodes. Summary of the invention

[0019] Purpose of the invention: The purpose of the present invention is to simplify the cathode design steps, improve processing efficiency, shorten the processing cycle, reduce clamping and positioning errors, ensure processing accuracy, and propose a closed component integrated cathode in-situ continuous full-surface electrolytic processing method.

[0020] Technical solution: A closed component integrated cathode in-situ continuous full-surface electrolytic machining tool, characterized in that: it includes a five-sided integrated cathode and a fixture; the five-sided integrated cathode includes an insulating fixed support with a hollow structure, and its end is equipped with an end surface machining cathode, and a liquid outlet is opened on the end surface machining cathode; the four sides of the insulating fixed support are respectively equipped with a blade basin surface machining cathode, a blade back surface machining cathode, a wheel hub surface machining cathode, and a blade crown surface machining cathode; the above-mentioned end surface machining cathode, blade basin surface machining cathode, blade back surface machining cathode, wheel hub surface machining cathode, and blade crown surface machining cathode are independently energized and not conductive to each other; the fixture includes a cathode rod, and the cathode rod is a hollow structure. The structure has a liquid inlet channel inside, the upper end of the five-sided integrated cathode is fixed to the cathode rod, the upper part of the cathode rod is fixed to the first moving axis and connected to the liquid inlet pipeline; the tooling fixture also includes a support plate, an insulating pad, a liquid sealing chamber, and a flexible sealing cover from bottom to top; the insulating pad is close to the upper end surface of the support plate, and is provided with a plurality of reflux grooves, the positions of which correspond one by one to the positions of the blade channel, and are used to accommodate part of the end surface cathode extending after the processing is completed, and the lower end surface of the closed component blank is in contact with the upper end surface of the insulating pad; the liquid sealing chamber is close to the upper end surface of the closed component blank, and is used to accommodate the five-sided integrated cathode to ensure that there is no interference when it moves up and down; the above is located at the upper part of the liquid sealing chamber.

[0021] The closed component integrated cathode in-situ continuous full-surface electrolytic machining device is characterized by: it also includes a driving device; the driving device includes a first moving axis, a second moving axis, and a first rotating axis; the first moving axis is fixed to the second moving axis and moves with it, and the moving direction of the first moving axis is perpendicular to the moving direction of the second moving axis; the upper end face of the first rotating spindle is connected to and fits the support plate, which can drive the closed component blank to rotate, and its axis is parallel to the moving direction of the first moving axis.

[0022] The closed component integrated cathode in-situ continuous full-surface electrolytic machining method is characterized by: Step 1: Install the support plate, insulating pad, and closed component blank, fix the integrated cathode to the cathode rod, install the integrated cathode, sealing liquid chamber, and flexible sealing cover, measure and locate the fixture, closed component blank, and integrated cathode through the dial indicator, install the wire, and complete the tool setting. Turn on the electrolyte circulation system, exhaust system, and turn on the electrolytic machining power supply; Step 2: Drive the five-sided integrated cathode to the optimal feeding position for blade channel processing, and the partitioned energized reversing feed matching system automatically energizes the end face processing cathode, and then drives the first motion axis to feed the five-sided integrated cathode downward along the axial direction of the closed component, and at the same time drives the first rotation axis to rotate the closed component blank around its axis to complete the rough processing of the blade channel; Step 3: At the same workstation, the partitioned energized reversing feed matching system automatically switches to the blade basin surface processing cathode or the blade back surface processing cathode to be energized, drives the five-sided integrated cathode to the optimal feeding position of the blade basin or blade back to be processed, keeps the five-sided integrated cathode fixed, drives the first rotating axis to drive the closed component blank to rotate toward the corresponding cathode surface, and completes the electrolytic finishing of the blade basin surface or the blade back surface; Step 4: At the same workstation, the partitioned energized reversing feed matching system automatically switches to the cathode for processing the blade back surface or the blade basin surface on the other side to draw electricity, drives the five-sided integrated cathode to the optimal feeding position of the blade back or blade basin to be processed, keeps the five-sided integrated cathode fixed, drives the first rotating axis to drive the closed component blank to rotate toward the corresponding cathode surface, and completes the electrolytic finishing of the blade back surface or blade basin surface; Step 5: At the same workstation, the zoned energized reversing feed matching system automatically switches to the hub surface machining cathode or the blade crown surface machining cathode to draw electricity, drives the five-sided integrated cathode to the optimal feeding position of the hub profile or the blade crown profile, keeps the closed component blank fixed, drives the second motion axis to make the five-sided integrated cathode feed in the same direction toward the surface to be machined, and completes the electrolytic finishing of the hub profile or the blade crown profile; Step 6: At the same workstation, the partitioned energized reversing feed matching system automatically switches to the blade crown surface processing cathode or the hub surface processing cathode to draw electricity, drives the five-sided integrated cathode to the optimal feed position of the blade crown surface or the hub surface, keeps the closed component blank fixed, drives the second motion axis to make the five-sided integrated cathode feed in the direction of the surface to be processed, and completes the electrolytic finishing of the blade crown surface or the hub surface; Step 7: When the full-profile processing of the blade of a channel is completed, the partitioned power-on reversing feed matching system automatically turns off the power of the end face processing cathode, the blade basin surface processing cathode, the blade back surface processing cathode, the hub surface processing cathode, and the blade crown surface processing cathode, and drives the five-surface integrated cathode to reset to the initial processing position according to the set retraction program, and drives the closed component blank to rotate 360 / n deg, where n is the number of blades of the closed component, and repeats the above steps 2 to 7 to finally complete the processing of all blades of the closed component blank; Step 8: Turn off the electrolyte circulation system, exhaust system, electrolytic machining power supply and machine tool.

[0023] Beneficial effects: Compared with the prior art, the present invention has the following significant features: (1) An integrated cathode structure is provided. The five-sided integrated cathode consists of five parts: the end face processing cathode, the blade basin surface processing cathode, the blade back surface processing cathode, the hub surface processing cathode and the blade crown surface processing cathode. The parts are insulated from each other and connected and fixed as a whole through insulating support blocks, realizing "shape" integration and "electrical" separation, simplifying the cathode design.

[0024] (2) A method for integrated roughing and finishing of the entire surface of a closed component is provided. Each cathode of the five-sided integrated cathode is independently powered, and the segmented power control and matching of different feed directions of cathodes for processing different surfaces are achieved at the same workstation through the segmented power-on reversing feed matching system. The cathode of the surface is powered on during normal feeding to process the corresponding surface, and is powered off at other times, thus discretizing the electric field and realizing localized electrolysis, so that each processed surface can be dissolved in the normal direction, completing integrated roughing and finishing of the entire surface.

[0025] (3) The integrated cathode in-situ continuous full-surface electrolytic machining has high efficiency, low cost and short machining cycle. In-situ continuous full-surface electrolytic machining avoids the traditional electrolytic machining of coarse and fine separation cathodes. There is no need to design two sets of fixtures and two sets of cathodes, which reduces the cathode design and finishing time and simplifies the closed component blade channel full-surface machining process; the cathode structure is simplified, the cathode structure is easy to process, and a single cathode can be replaced separately after damage; the cathode can be designed and processed separately for the blade surface and assembled, which effectively improves the machining efficiency while reducing production costs.

[0026] (4) The integrated cathode partitioned electrification in-situ continuous full-surface electrolytic machining ensures the blade machining allowance and improves the machining accuracy and surface quality. The partitioned electrification machining method discretizes the electric field, realizes localized dissolution, effectively reduces stray corrosion in the non-machining area, ensures the uniformity of the blade machining allowance, and improves the surface quality; in-situ continuous electrolytic machining only requires one clamping to achieve the machining of all channels, avoiding the errors caused by repeated clamping and positioning processes, and improving the accuracy of electrolytic machining of closed components.

[0027] (5) The integrated cathode in-situ continuous full-surface electrolytic machining method has a wide range of applications and high machining flexibility. For other blade disk parts, the cathode surfaces can be designed specifically for machining.

[0028] The closed component integrated cathode in-situ continuous full-surface electrolytic processing tool is characterized in that each surface processed cathode of the above-mentioned five-sided integrated cathode is engaged with the insulating fixed support through a dovetail groove structure, and the cathode can be fixed without damaging the cathode surface. At the same time, the dovetail groove structure plays the role of a reinforcing rib, effectively increasing the rigidity of the thin-walled cathode.

[0029] The closed component integrated cathode in-situ continuous full-surface electrolytic machining tool is characterized in that the size of the backflow groove is larger than the size of the end surface machining cathode, and the depth is less than the thickness of the end surface machining cathode. The backflow groove can be used to accommodate the protruding part of the integrated cathode to prevent the tool from hitting the tool and seal the electrolyte at the same time, effectively ensuring the stability of the electrolyte pressure at the moment of blade channel machining penetration.

[0030] The closed component integrated cathode in-situ continuous full-surface electrolytic machining tool is characterized in that: the above-mentioned flexible sealing cover is composed of a bottom plate, a flexible sealing plate, and a cover plate from bottom to top; the bottom plate is close to the upper end surface of the sealing liquid chamber, and rectangular holes larger than the cathode rod are provided on the bottom plate and the cover plate. At the same time, a groove with a depth greater than the thickness of the flexible sealing plate is provided at the lower part of the cover plate. The groove is used to accommodate the flexible sealing plate to slide inside. The cathode rod passes through the bottom plate, the flexible sealing plate and the cover plate in turn to press the cover plate. The flexible sealing cover can meet the synchronous movement with the cathode to realize the function of flexible sealing. At the same time, the structure is simple and easy to disassemble. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a schematic diagram of the closed component integrated cathode in-situ continuous full-surface electrolytic machining method of the present invention; Figure 2 Schematic diagram of the integrated cathode structure; Figure 3 It is a schematic diagram of the insulating pad structure; Figure 4 Schematic diagram of the liquid sealing chamber structure; Figure 5This is a partial enlarged view of the in-situ continuous full-surface electrolytic processing of the integrated cathode in the present invention; Figure 6 It is a schematic diagram of the decomposition of the steps of in-situ continuous full-surface electrolytic machining of the integrated cathode in the present invention; Figure 7 It is a schematic diagram of the structure of the flexible sealing cover; Names of the numbers in the figure: 1-first rotating axis, 2-support plate, 3-insulating pad, 4-closed component blank, 5-integrated cathode, 6-liquid sealing chamber, 7-flexible sealing cover, 8-cathode rod, 9-second moving axis, 10-first moving axis, 11-end face processed cathode, 12-blade back face processed cathode, 13-hub face processed cathode, 14-blade basin face processed cathode, 15-insulating support body, 16-blade crown face processed cathode, 17-reverse flow groove, 18-hub profile, 19-blade basin profile, 20-blade crown profile, 21-blade back profile, 22-flexible sealing cover cover plate, 23-flexible sealing plate, 24-flexible sealing cover bottom plate. DETAILED DESCRIPTION

[0032] The technical solution of the present invention is further described below in conjunction with the accompanying drawings.

[0033] like Figure 1 and Figure 5 As shown, in the integrated cathode in-situ continuous full-surface electrolytic machining method of the present invention, the support disk 2 is installed on the first rotating shaft 1, the insulating pad 3 is tightly fixed to the support disk 2, and the reflow groove 17 is located on the upper end surface of the insulating pad 3. When the blade channel is about to be processed and penetrated, the electrolyte is rebounded back to the processing area under the action of the reflow groove and will not disperse. The closed component blank 4 is attached and fixed to the upper end surface of the insulating pad 3, the position of the blade channel to be processed corresponds to the reflow groove 17 one by one, and the bottom of the sealing liquid cavity 6 is close to the upper end surface of the closed component blank 4. The flexible sealing cover 7 is located at the upper part of the sealing liquid cavity 6, and the flexible sealing cover bottom plate 24 is close to the upper end surface of the sealing liquid cavity 6. The cathode rod 8 passes through the rectangular hole, and drives the flexible sealing plate 23 to cooperate with the cover plate 22 while moving horizontally to achieve flexible sealing. The upper part of the cathode rod 8 is fixed on the first moving shaft 10 and connected to the liquid inlet pipeline. The five-face integrated cathode 5 includes five processing parts, namely, the end surface processing cathode 11, the blade basin surface processing cathode 14, the blade back surface processing cathode 12, the hub surface processing cathode 13, and the blade crown surface processing cathode 16, and an insulating fixed support part 15. The five profile processing cathodes are installed and fixed on the insulating support 15, and are isolated from each other by the insulating support 15 to achieve independent power supply. The five-face integrated cathode 5 is initially located in the annular cavity of the sealing liquid cavity 6 and is fixed on the cathode rod 8. The electrolyte flows from the cathode rod 8 through the hollow insulating support 15 inside and finally sprays out from the flushing port of the end surface processing cathode 11 to supply liquid to the processing area.

[0034] The integrated cathode in-situ continuous full-surface electrolytic machining process of the present invention comprises the following steps: Step S1: Install and fix the support plate 2, the insulating pad 3, the closed component blank 4, and the liquid sealing chamber 6 on the first rotating axis 1 of the machine tool in sequence from bottom to top, which can achieve a motion accuracy of 0.001° rotation step. The central rotation axis of the closed component blank 4 coincides with the axis of the first rotating axis 1 of the machine tool. Place the integrated cathode 5 and the cathode rod 8 in the annular cavity of the liquid sealing chamber 6, install and fix the flexible sealing cover 7, connect the other end of the cathode rod 8 to the first moving axis 10, open the electrolyte circulation system and the exhaust system, and turn on the electrolytic machining power supply.

[0035] Step S2: Connect the five-sided integrated cathode 5 to the partitioned energized reversing feeding matching system respectively. The cathode is installed on the first motion axis 10 through the cathode rod 8. The first motion axis 10 is installed on the second motion axis 9. The two can achieve a translational motion accuracy of 0.001mm.

[0036] Step S3: Start the cathode CNC platform and the closed component blank CNC platform, drive the integrated cathode 5 to the optimal feeding position for machining the blade channel, start the electrolyte circulation system to introduce electrolyte, connect the electrolytic machining power supply, and automatically energize the end face machining cathode 11 through the partitioned energizing reversing feed matching system. Run the CNC program according to the set machining trajectory to drive the integrated cathode to feed axially along the closed component blank. At the same time, the first rotating axis 1 assists with the rotational motion to complete the pre-machining of the blade channel.

[0037] Step S4-1: After the pre-processing of the blade grid channel is completed, the partitioned energized reversing feed matching system automatically controls the end face processing cathode 11 to be powered off, and drives the five-sided integrated cathode 5 to move to the optimal feed position of the blade basin surface to be processed. At the same workstation, the partitioned energized reversing feed matching system automatically energizes the blade basin surface processing cathode 14, and drives the closed component blank to rotate around the first rotation axis 1, so that it runs the CNC machining program according to the predetermined machining route to complete the electrolytic finishing of the blade basin surface.

[0038] Step S4-2: After completing the electrolytic finishing of the blade basin surface, the partitioned energized reversing feed matching system automatically controls the blade basin surface processing cathode 14 to be powered off, and drives the five-sided integrated cathode 5 to move to the optimal feed position of the blade back surface 21 to be processed. At the same workstation, the partitioned energized reversing feed matching system automatically enables the blade back surface processing cathode to be energized 12, and drives the closed component blank 4 to rotate around the first rotation axis 1 in the opposite direction to step S4-1, so that it runs the CNC machining program according to the predetermined machining route to complete the electrolytic finishing of the blade back surface 21.

[0039] Step S4-3: After completing the electrolytic finishing of the blade back surface, the partitioned energized reversing feed matching system automatically controls the power off of the blade back surface processing cathode 12, and drives the five-sided integrated cathode 5 to move to the optimal feed position of the hub surface 18 to be processed. At the same workstation, the partitioned energized reversing feed matching system automatically energizes the hub surface processing cathode 13, and drives the second motion axis 9 to feed the cathode along the normal direction of the hub surface, thereby completing the electrolytic finishing of the hub surface 18.

[0040] Step S4-4: After completing the electrolytic finishing of the hub surface, the partitioned energized reversing feed matching system automatically controls the hub surface processing cathode 13 to be powered off, and drives the five-sided integrated cathode 5 to move to the optimal feed position of the blade crown surface 20 to be processed. At the same workstation, the partitioned energized reversing feed matching system automatically energizes the blade crown surface processing cathode 16, and drives the second motion axis 9 to feed the cathode along the normal direction of the blade crown surface, completing the full-surface electrolytic machining of a single blade channel.

[0041] Step S5: After the full-profile machining of a blade cascade channel is completed, the partitioned energized reversing feed matching system automatically makes the end face machining cathode 11, the blade basin surface machining cathode 14, the blade back surface machining cathode 12, the hub surface machining cathode 13 and the blade crown surface machining cathode 16 all non-energized, and drives the five-face integrated cathode to reset to the initial machining position according to the set retraction program, drives the closed component to rotate 360 / n deg, where n is the number of blades of the closed component, repeats the above processing step S4, and finally completes the full-profile electrolytic machining of all blades of the closed component blank 4. Finally, the electrolytic machining power supply is disconnected, the exhaust system is turned off, and the electrolyte circulation system is turned off to stop the liquid supply.

Claims

1. A closed component integrated cathode in-situ continuous full-surface electrolytic machining tool, characterized in that: It comprises a five-sided integrated cathode (5) and a fixture; The five-sided integrated cathode (5) comprises an insulating fixed support (15) with a hollow structure, an end surface processing cathode (11) is installed at its end, and a liquid outlet is opened on the end surface processing cathode (11); the four side surfaces of the insulating fixed support (15) are respectively installed with a blade basin surface processing cathode (14), a blade back surface processing cathode (12), a wheel hub surface processing cathode (13), and a blade crown surface processing cathode (16); the end surface processing cathode (11), the blade basin surface processing cathode (14), the blade back surface processing cathode (12), the wheel hub surface processing cathode (13), and the blade crown surface processing cathode (16) are independently electrically connected and are not mutually conductive; The fixture comprises a cathode rod (8), which is a hollow structure with a liquid inlet channel inside. The upper end of the five-sided integrated cathode (5) is fixed to the cathode rod (8), and the upper part of the cathode rod (8) is fixed to the first moving shaft (10) and connected to the liquid inlet pipeline. The fixture further comprises, from bottom to top, a support plate (2), an insulating pad plate (3), a liquid sealing chamber (6), and a flexible sealing cover (7). The insulating pad plate (3) is in close contact with the upper end surface of the support plate (2), and is provided with a plurality of reflux grooves (17). The positions of the reflux grooves correspond to the positions of the blade channel one by one, and are used to accommodate the part of the end surface cathode (11) that extends out after processing. The lower end surface of the closed component blank (4) is in contact with the upper end surface of the insulating pad plate (3); the liquid sealing chamber (6) is in close contact with the upper end surface of the closed component blank, and is used to accommodate the five-sided integrated cathode (5) to ensure that there is no interference when they move up and down; the above-mentioned is located at the upper part of the liquid sealing chamber (6).

2. The closed component integrated cathode in-situ continuous full-surface electrolytic machining tool according to claim 1, characterized in that: Each of the processed cathode surfaces of the five-sided integrated cathode (5) is engaged with the insulating fixed support (15) through a dovetail groove structure.

3. The closed component integrated cathode in-situ continuous full-surface electrolytic machining tool according to claim 1, characterized in that: The size of the counterflow groove is larger than the size of the end surface processed cathode, and the depth is smaller than the thickness of the end surface processed cathode (11).

4. The closed component integrated cathode in-situ continuous full-surface electrolytic machining tool according to claim 1, characterized in that: The flexible sealing cover is composed of a bottom plate (24), a flexible sealing plate (23) and a cover plate (22) from bottom to top; the bottom plate (24) is in close contact with the upper end surface of the sealing liquid chamber (6); a rectangular hole larger than the cathode rod (8) is provided on the bottom plate (24) and the cover plate (22); at the same time, a groove with a depth greater than the thickness of the flexible sealing plate (23) is provided at the lower part of the cover plate (22); the groove is used to accommodate the flexible sealing plate (23) to slide inside; the cathode rod (8) passes through the bottom plate (24), the flexible sealing plate (23) and the cover plate (22) in sequence, and presses the cover plate (22); the cathode rod (8) drives the flexible sealing plate (23) while moving horizontally to achieve flexible sealing.

5. The closed component integrated cathode in-situ continuous full-surface electrolytic machining device according to claim 1, characterized in that: The invention also comprises a driving device; the driving device comprises a first moving shaft (10), a second moving shaft (9), and a first rotating shaft (1); the first moving shaft (10) is fixed to the second moving shaft (9) and moves therewith, and the moving direction of the first moving shaft (10) is perpendicular to the moving direction of the second moving shaft (9); the upper end surface of the first rotating main shaft (1) is connected to and abuts against the supporting plate (2), and can drive the closed component blank (4) to rotate, and its axis is parallel to the moving direction of the first moving shaft (10).

6. The method for in-situ continuous full-surface electrolytic machining of closed components with integrated cathode according to claim 5, characterized in that: Step 1: Install the support plate (2), insulating pad (3), and closed component blank (4), fix the integrated cathode (5) to the cathode rod (8), install the integrated cathode (5), the sealing liquid chamber (6), and the flexible sealing cover (7), measure and locate the fixture, the closed component blank, and the integrated cathode through a dial indicator, install the wire, and complete the tool setting. Turn on the electrolyte circulation system and exhaust system, and turn on the electrolytic machining power supply; Step 2: driving the five-sided integrated cathode (5) to the optimal feeding position for blade channel processing, the partitioned energized reversing feed matching system automatically energizes the end face processing cathode (11), and then driving the first motion axis (10) to feed the five-sided integrated cathode (5) downward along the axial direction of the closed component, and at the same time driving the first rotating axis (1) to rotate the closed component blank (4) around its axis, thereby completing the rough processing of the blade channel; Step 3: At the same workstation, the partitioned energized reversing feed matching system automatically switches to energize the blade basin surface processing cathode (14) or the blade back surface processing cathode (12), drives the five-sided integrated cathode (5) to the optimal feed position of the blade basin or blade back surface to be processed, keeps the five-sided integrated cathode (5) fixed, drives the first rotating shaft (1) to drive the closed component blank (4) to rotate toward the corresponding cathode surface, and completes the electrolytic finishing of the blade basin surface (19) or the blade back surface (21); Step 4: At the same workstation, the partitioned energized reversing feed matching system automatically switches to the blade back processing cathode (12) or blade basin surface processing cathode (14) on the other side to draw electricity, drive the five-sided integrated cathode (5) to the optimal feeding position of the blade back (21) or blade basin (19) to be processed, keep the five-sided integrated cathode (5) fixed, drive the first rotating shaft (1) to drive the closed component blank (4) to rotate toward the corresponding cathode surface, and complete the electrolytic finishing of the blade back surface (21) or blade basin surface (19); Step 5: At the same workstation, the zoned energized reversing feed matching system automatically switches to the hub surface processing cathode (13) or the blade crown surface processing cathode (16) to draw electricity, drive the five-sided integrated cathode (5) to the optimal feeding position of the hub profile (18) or the blade crown profile (20), keep the closed component blank (4) fixed, drive the second motion axis (9) to make the five-sided integrated cathode (5) feed in the direction of the surface to be processed, and complete the electrolytic finishing of the hub profile (18) or the blade crown profile (20); Step 6: At the same workstation, the partitioned energized reversing feed matching system automatically switches to the blade crown surface processing cathode (16) or the wheel hub surface processing cathode (13) to draw electricity, drive the five-sided integrated cathode (5) to the optimal feeding position of the blade crown profile (20) or the wheel hub profile (18), keep the closed component blank (4) fixed, drive the second motion axis (9) to make the five-sided integrated cathode (5) feed in the direction of the surface to be processed, and complete the electrolytic finishing of the blade crown profile (20) or the wheel hub profile (18); Step 7: When the full-profile processing of the blade of a channel is completed, the partitioned power-on reversing feed matching system automatically turns off the power to the end surface processing cathode (11), the blade basin surface processing cathode (14), the blade back surface processing cathode (12), the hub surface processing cathode (13), and the blade crown surface processing cathode (16), and drives the five-surface integrated cathode (5) to reset to the initial processing position according to the set retraction program, and drives the closed component blank (4) to rotate 360 / n deg, where n is the number of blades of the closed component, and repeats the above steps 2 to 7 to finally complete the processing of all blades of the closed component blank; Step 8: Turn off the electrolyte circulation system, exhaust system, electrolytic machining power supply and machine tool.

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