A gas turbine dynamic ring part repair process method

Abstract

The present application aims to provide a gas turbine ring part repair process, belonging to the field of gas turbine. The process comprises the following steps: (1) grinding and polishing; (2) inspection; (3) fine grinding; (4) cleaning; (5) inspection; (6) laser engraving; (7) secondary processing; (8) inspection; (9) warehousing. The present application greatly shortens the processing cycle, reduces the finished product, and can create good economic benefits.

Description

Technical Field

[0001] This invention relates to a gas turbine repair method, specifically a method for repairing rotating ring components. Background Technology

[0002] As an advanced and complex set of power machinery, the development level of gas turbines is one of the important indicators of a country's high-tech capabilities and scientific and technological strength, and has outstanding strategic significance. With the continuous development of the localization process of gas turbines in my country, precision machining technology has become one of the key factors restricting the stable operation of the entire gas turbine, the improvement of engine performance, and the reduction of fuel consumption. Dynamic ring parts are important components in the assembly of gas turbines, cooperating with graphite rings. They bear the important functions of dynamic-static transition and oil / gas sealing. The design precision of these parts is extremely high, and the manufacturing process is complex, making it a typical precision machining process. One particularly challenging aspect is machining a flag-shaped shallow oil film groove with a depth of 0.018 mm and a tolerance of 0.0045 mm at a designated position on the ultra-precision coated end face with a flatness of 0.001 mm and a surface roughness of 0.04 mm. This technique has always been a difficult point in the industry, resulting in a low yield rate for the machined parts.

[0003] The overhaul time for gas turbines is determined based on the operating environment and operating time, with a mid-term overhaul approximately every 2-4 years. During the disassembly of the gas turbine, rotating rings are a key focus of inspection. After prolonged operation, the rotating rings interact with the graphite rings, causing wear on the rotating ring surface. Coordinate measuring machine (CMM) inspection reveals changes in flatness and flag groove dimensions, failing to meet installation requirements and necessitating replacement with new rotating rings. Rotating ring machining is a difficult part, with a long production cycle and high cost, impacting the gas turbine reassembly schedule. The process route from raw material to finished product is as follows: Figure 1 As shown. Summary of the Invention

[0004] The purpose of this invention is to provide a rework process for gas turbine motor ring parts to achieve an installation-ready state.

[0005] The objective of this invention is achieved as follows:

[0006] This invention includes the following steps:

[0007] (1) Grinding and polishing;

[0008] (2) Inspection;

[0009] (3) Fine grinding;

[0010] (4) Cleaning;

[0011] (5) Inspection;

[0012] (6) Laser engraving and milling;

[0013] (7) Secondary processing;

[0014] (8) Inspection;

[0015] (9) Put into storage.

[0016] The present invention may also include:

[0017] 1. In step (1) grinding and polishing, 3000# diamond abrasive and water are mixed evenly and added to the grinding and polishing machine. The moving ring is placed in the grinding machine. The grinding machine table rotates at 40r / min. The grinding liquid is flushed for 2s every 30s. Grinding is carried out for 20min to remove the graphite ring residue on the surface of the moving ring.

[0018] 2. In step (2), the actual requirement for flatness of the three coordinate measuring machine is 0.001mm, and the actual requirement for depth of the flag groove of the moving ring is 0.018+0.0021-0.0015mm. The actual value is used to determine whether to continue to use or to rework. If rework is required, the thickness of the chrome plating layer on the working surface of the moving ring is measured, and the thickness requirement is within the range of 0.07-0.1mm.

[0019] 3. In step (3) fine grinding, 0.25KG of 1200 mesh boron carbide powder and 200ML of fully synthetic water-soluble cutting fluid are used. Water is added to fill a solution tank with a volume of 0.009m³. The moving ring is placed in the grinding machine. The grinding machine table rotates at 45r / min. The grinding fluid is flushed for 1s every 35s and the grinding is carried out for 45min. After grinding stops, the surface of the moving ring is wiped and the flatness of the moving ring working surface is checked on the flat crystal using the interference method. If it is not qualified, the grinding machine table is adjusted appropriately. In the process of adjusting the grinding machine table, when the grinding surface of the part is higher on the outside and lower on the inside, the screw in the middle of the grinding disc is tightened. The grinding platform grinds the workpiece by the principle of yin-yang grinding. In the process of adjusting the grinding machine table, when the part is higher on the outside and lower on the inside, the grinding platform is lower on the outside and higher on the inside. Tighten the screw to lower the grinding platform until the grinding is qualified.

[0020] 4. Step (4) Cleaning: Remove the abrasive sand from the oil storage tank by ultrasonic cleaning.

[0021] 5. Step (5) Inspection: After the parts are cleaned, use a coordinate measuring machine to inspect the actual values ​​of the parts’ dimensions, chrome plating thickness, flatness and flag groove depth.

[0022] 6. In step (6) laser engraving and milling, place the part on the fixture and support it with a three-jaw chuck. Process a window of the same shape and size as the oil reservoir on a 0.3mm thick iron sheet. Cover the moving ring with the iron sheet so that the window on the iron sheet coincides with the oil reservoir of the moving ring. Run the single-segment marking program and move the moving ring to the appropriate position according to the position of the flag groove. Select the matching hook according to the part with different drawing numbers and use a hot melt gun to stick the hook and the part together. Place it in the fixture, with the hook against the limit rod on the fixture. Check if there is a gap between the hook and the limit rod. The first marking count is less than 60 times. Then select the graphic to be marked and click the general plane marking in the next process.

[0023] 7. The secondary processing in step (7) refers to reinstalling the parts for secondary processing if the dimensions are not qualified: if the difference between the deepest and shallowest grooves in the measurement results is less than 0.003, the marking depth for each time is obtained based on the first marking count / the average of the deepest and shallowest measured values, and the marking count is determined by calculating the final dimension minus the average value; the selected graphic is repeatedly selected, the general plane marking is clicked, the motor is repeatedly reset, and the start is clicked after the motor is reset.

[0024] 8. The inspection in step (8) is to check the actual values ​​of the part size, flatness and flag groove depth using a coordinate measuring machine.

[0025] The advantages of this invention are: it greatly shortens the processing cycle, reduces the cost of finished products, and can create excellent economic benefits. Attached Figure Description

[0026] Figure 1 This is a process route diagram from raw material to finished product using traditional methods;

[0027] Figure 2 This is a flowchart of the present invention. Detailed Implementation

[0028] The invention will now be described in more detail with reference to the accompanying drawings:

[0029] Combination Figure 1-2 The present invention discloses a rework process for a gas turbine motor ring, comprising the following steps:

[0030] Step 1: Grinding and Polishing

[0031] Step 2: Inspection

[0032] Step 3: Fine grinding

[0033] Step 4: Cleaning

[0034] Step 5: Inspection

[0035] Step 6: Laser engraving and milling

[0036] Step 7: Secondary processing (optional)

[0037] Step 8: Inspection

[0038] Step 9: Inventory Storage

[0039] Step 1: Grinding and polishing. After working with the graphite ring for a long time, the working surface of the rotating ring disassembled from the overhaul machine has graphite ring residue attached to the flag groove on the surface of the rotating ring. Alcohol wiping and ultrasonic cleaning cannot remove it. Select 3000# diamond abrasive and water, mix them evenly and add them to the grinding and polishing machine. Place the rotating ring into the grinding machine.

[0040] Step 1: Grinding and polishing. The grinding machine table rotates at 40 rpm. The grinding slurry is rinsed for 2 seconds every 30 seconds. Grinding lasts for 20 minutes to remove graphite ring residue from the surface of the moving ring.

[0041] Step 2 Inspection: After grinding, the flatness is checked by a coordinate measuring machine. The actual flatness requirement is 0.001mm and the depth of the flag groove is also checked.

[0042] Step 2 inspection: The actual required depth of the flag-shaped groove in the dynamic ring design is 0.018 + 0.0021 - 0.0015 mm. The actual value is obtained by measurement, and the decision is made on whether to continue using it or to rework it based on the actual value.

[0043] Step 2 Inspection: Based on the actual values ​​of the flag-shaped groove of the moving ring, if rework is required, the thickness of the chrome plating layer on the working surface of the moving ring needs to be measured. The thickness requirement is within the range of 0.07-0.1mm.

[0044] Step 3: Fine grinding. Use 0.25KG of 1200-mesh boron carbide powder, 200ML of fully synthetic water-soluble cutting fluid, and fill the solution tank with water to a volume of 0.009m³. Place the moving ring into the grinding machine, and rotate the grinding machine table at 45r / min. Pour the grinding fluid in for 1s every 35s and grind for 45min.

[0045] Step 3: Fine grinding. After grinding stops, wipe the surface of the moving ring and use the interference method to check whether the flatness of the working surface of the moving ring is qualified on the flat crystal.

[0046] Step 3: Fine grinding. If the result is not satisfactory, adjust the grinding machine's worktable accordingly.

[0047] Step 3, fine grinding: During the process of adjusting the grinding machine's worktable, when the grinding surface of the part appears to be higher on the outside and lower on the inside, it is necessary to tighten the screw in the middle of the grinding disc. The grinding platform grinds the workpiece using a combination of yin and yang grinding.

[0048] Step 3, fine grinding: During the process of adjusting the grinding machine's worktable, if the outer part is higher than the inner part, and the grinding platform is lower on the outside and higher on the inside, the screws need to be tightened to lower the grinding platform until the grinding is qualified.

[0049] Step 4: Cleaning. Since this is a reworked rotating ring, the oil reservoir on the rotating ring surface has already been machined. During the grinding process, a large amount of abrasive sand remains in the oil reservoir, requiring ultrasonic cleaning to remove the abrasive sand.

[0050] Step 5 Inspection: After the parts are cleaned, use a coordinate measuring machine to inspect the actual values ​​of the parts' dimensions, chrome plating thickness, flatness, and flag groove depth.

[0051] Step 6: Laser milling and part installation: Place the part on the fixture and support it with a three-jaw chuck. Since the oil storage tank of the part has been processed, the vertical edge of the flag-shaped groove is connected to the oil storage tank according to the drawing requirements. The position of the flag-shaped groove is difficult to determine. A window with the same shape and size as the oil storage tank is processed on a 0.3mm thick iron sheet. The iron sheet is placed on the moving ring so that the window of the iron sheet coincides with the oil storage tank of the moving ring. The single-stage running marking program moves the moving ring to the appropriate position according to the position of the flag-shaped groove.

[0052] Step 6: Laser milling and part installation: Select the appropriate hook according to the part number and use a hot melt gun to glue the hook to the part. Place it in the fixture, with the hook resting against the limit rod on the fixture. Check for gaps between the hook and the limit rod. The limit rod serves to repeatedly position the part after multiple clamping operations.

[0053] Step 6: Laser engraving and milling. Set the number of markings. Based on past marking experience, the first marking should be less than 60 times. Then select the graphic to be marked. For the next process, click on General Planar Marking.

[0054] Step 6 Laser engraving and milling, coordinate setting: According to the number of flag slots in the part drawing, they can be divided into three categories.

[0055] The flag-shaped slot has 30 stations; the coordinates of the first slot are 222.4 on the X-axis and 288.8 on the Y-axis.

[0056] The flag-shaped slot has 40 stations; the coordinates of the first slot are 222.4 on the X-axis and 313.8 on the Y-axis.

[0057] The flag-shaped slot has 50 stations; the coordinates of the first slot are 222.4 on the X-axis and 341.3 on the Y-axis.

[0058] Step 6 Laser engraving and milling, height setting: For example, when the workpiece thickness is 24mm, the Z-axis height is set to 387; when the workpiece thickness is 23mm, the Z-axis height is set to 388; and when the workpiece thickness is 25mm, the Z-axis height is set to 386. Since the zero point of the Z-axis of the equipment is at the top, the Z-axis height decreases as the thickness of the part increases, and vice versa.

[0059] Step 7: Secondary processing. If the dimensions are not up to standard after the first processing inspection, the parts need to be reinstalled and processed again.

[0060] Step 7: Secondary processing. After the first processing inspection, if the difference between the deepest and shallowest grooves in the measurement results is less than 0.003, the marking depth for each step is obtained by dividing the first marking count by the average of the deepest and shallowest measurements. The number of marking steps is determined by subtracting the average value from the final dimension. During the first processing, select the desired shape, click "General Plane Marking," repeat "Motor Reset," and then click "Start."

[0061] Step 7: Secondary processing. After the first processing inspection, if the difference between the deepest and shallowest grooves in the measurement results is greater than 0.003, obtain the marking depth for each step based on the first marking count divided by the deepest value. Determine the marking count by subtracting the average value from the final dimension. To repeat the first processing, select the desired shape, click "General Plane Marking," select the desired shape again, and click "General Plane Marking."

[0062] Step 7: Secondary processing. After the first processing inspection, some flag-shaped grooves may not reach the required dimensions and need to be re-marked based on the measurement results. The parts need to be reinstalled and processed. The number of markings is determined based on the difference between the shallowest groove and the final dimension. Repeat the process from the first processing: select the desired shape, click "General Plane Marking," check "Re-marking," select the groove number to be re-marked, and select "1 time." Finally, repeat the motor reset process. After the motor reset, click "Start."

[0063] Step 8: Inspection. Use a coordinate measuring machine to check the actual values ​​of the part's dimensions, flatness, and flag groove depth.

[0064] Step 9: Warehousing: Qualified parts are put into storage.

Claims

1. A rework process for gas turbine motor ring parts, characterized by: Includes the following steps: (1) Grinding and polishing; (2) Inspection; the actual requirement for flatness of the three coordinate measuring machine is 0.001mm, and the actual requirement for depth of the flag groove of the moving ring is 0.018+0.0021-0.0015mm. Based on the actual value, it is determined whether to continue to use or to rework; if rework is required, the thickness of the chrome plating layer on the working surface of the moving ring is measured, and the thickness requirement is within the range of 0.07-0.1mm. (3) Fine grinding; Use 0.25KG of 1200 mesh boron carbide powder, 200ML of fully synthetic water-soluble cutting fluid, and fill the solution tank with water to a volume of 0.009m³. Place the moving ring into the grinding machine, rotate the grinding machine table at 45r / min, and flush the grinding fluid for 1s every 35s. Grind for 45min. After grinding stops, wipe the surface of the moving ring and check the flatness of the moving ring working surface on the flat crystal using the interference method. If it is not qualified, adjust the grinding machine table appropriately. In the process of adjusting the grinding machine table, when the grinding surface of the part is higher on the outside and lower on the inside, adjust the screw in the middle of the grinding disc. The grinding platform grinds the workpiece by the principle of yin-yang grinding. In the process of adjusting the grinding machine table, when the part is higher on the outside and lower on the inside, the grinding platform is lower on the outside and higher on the inside. Tighten the screw to lower the grinding platform until the grinding is qualified. (4) Cleaning; (5) Inspection; (6) Laser engraving and milling; Place the part on the fixture and support it with a three-jaw jack. Machin a window of the same shape and size as the oil reservoir on a 0.3mm thick iron sheet. Cover the moving ring with the iron sheet so that the window on the iron sheet coincides with the oil reservoir of the moving ring. Run the single-segment marking program and move the moving ring to the appropriate position according to the position of the flag groove. Select the matching hook according to the part with different drawing numbers and use a hot melt gun to glue the hook and the part together. Place it in the fixture, with the hook against the limit rod on the fixture. Check if there is a gap between the hook and the limit rod. The first marking count is less than 60 times. Then select the graphic to be marked and click the general plane marking in the next process. (7) Secondary processing; (8) Inspection; (9) Put into storage.

2. The rework process method for gas turbine motor ring parts according to claim 1, characterized in that: In step (1) grinding and polishing, 3000# diamond abrasive and water are mixed evenly and added to the grinding and polishing machine. The moving ring is placed in the grinding machine. The grinding machine table rotates at 40r / min. The grinding fluid is flushed for 2s every 30s. Grinding is carried out for 20min to remove the graphite ring residue on the surface of the moving ring.

3. The rework process method for gas turbine motor ring parts according to claim 1, characterized in that: Step (4) Cleaning: Remove the abrasive sand from the oil storage tank by ultrasonic cleaning.

4. The rework process method for gas turbine motor ring parts according to claim 1, characterized in that: Step (5) Inspection: After the parts are cleaned, the actual values ​​of the part dimensions, chrome plating thickness, flatness and flag groove depth are inspected using a coordinate measuring machine.

5. The rework process method for gas turbine motor ring parts according to claim 1, characterized in that: The second processing step (7) refers to reinstalling the parts for secondary processing if the dimensions are not qualified: if the difference between the deepest and shallowest grooves in the measurement results is less than 0.003mm, the average marking depth for each time is obtained based on the average value of the deepest and shallowest measurements, and the number of markings is determined by subtracting the average value from the final dimension; the selected graphic is selected repeatedly, the general plane marking is clicked, the motor is reset repeatedly, and the start is clicked after the motor is reset.

6. The rework process method for gas turbine motor ring parts according to claim 1, characterized in that: The inspection in step (8) is to check the actual values ​​of the part's dimensions, flatness, and flag groove depth using a coordinate measuring machine.

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