High-quality and high-efficiency machining device and method for complex cavity of high-temperature alloy pressure reducing valve

Abstract

The invention discloses a high-quality and high-efficiency machining device and method for a complex cavity of a high-temperature alloy pressure reducing valve. The device comprises a machine tool, a large-amplitude ultrasonic vibration drilling mechanism, an X-axis guide rail, a two-dimensional ultrasonic vibration turning mechanism and a tool nose height precision detection mechanism. A Z-axis guide rail and a driving assembly are mounted on the machine tool; the driving assembly is used for driving the workpiece clamp to rotate; the large-amplitude ultrasonic vibration drilling mechanism is connected to the Z-axis guide rail in a sliding mode through a tailstock moving assembly. The X-axis guide rail is slidably connected to the Z-axis guide rail through a Z-axis moving assembly, and the X-axis guide rail is slidably connected with an X-axis moving assembly. The two-dimensional ultrasonic vibration turning mechanism is installed on the X-axis moving assembly through the tool nose height precision adjusting mechanism. The tool nose height precision detection mechanism is installed on the driving assembly and used for detecting the height of the two-dimensional ultrasonic vibration turning mechanism. The size precision and the shape precision of machining of the complex cavity of the high-temperature alloy pressure reducing valve are guaranteed, the number of tools and tool abrasion are reduced, and the machining quality and efficiency are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of precision and efficient machining of complex cavity structures of difficult-to-machine metal materials, and particularly to a high-quality and efficient machining device and method for the complex cavity of a superalloy pressure reducing valve. Background Technique

[0002] As an important component of the afterburner regulator in an aeroengine, the machining accuracy and quality of the superalloy pressure reducing valve have an important impact on the thrust regulation accuracy, response speed, working stability and reliability of the aeroengine, and are crucial for ensuring the flight safety and performance of the aircraft. The function of the superalloy pressure reducing valve is to precisely control the intake air volume of the engine afterburner regulator. During operation, the air volume control is mainly achieved by adjusting the gap between the needle valve and the cavity structure on the pressure reducing valve housing. To achieve the air volume adjustment function, the cavity structure on the superalloy pressure reducing valve is complex (including multiple stepped holes (hole diameter less than 15 mm) and threaded holes), and the machining accuracy requirements are high.

[0003] Superalloys are typical difficult-to-machine materials, with characteristics such as low thermal conductivity (10 - 40 W / (m·°C)), high strength and hardness, and non-uniform microstructure and micro-mechanical properties (in the microstructure, in addition to the matrix phase, there are also γ and γ′ and the composite phase composed of the two). During machining, the amplitude and fluctuation of the cutting force are large, the cutting zone temperature is high, and under the combined action of high temperature and alternating impact of large cutting force, the tool wear and chipping are serious, making it difficult to guarantee the machining accuracy and surface quality of the parts. The machining process of the complex cavity structure of the existing superalloy pressure reducing valve is complex (requiring two machine tools, a general lathe and a precision CNC lathe, to perform rough machining, semi-finishing and finishing processes such as drilling, expanding, boring and tapping step by step), and the number of tools is as many as more than a dozen (including 4 drills, 7 boring tools, 1 tap, etc.). Especially restricted by the part structure, it is difficult for the cooling medium to effectively reach the cutting zone during machining, resulting in difficult cooling, and the tool is slender with poor rigidity, and problems such as serious tool wear, poor machining accuracy and surface quality of the parts, low machining efficiency and high cost are prominent.

[0004] Therefore, a high-quality and efficient machining device and method for the complex cavity of a superalloy pressure reducing valve are proposed. Summary of the Invention

[0005] The purpose of the present invention is to provide a high-quality and efficient machining device and method for the complex cavity of a superalloy pressure reducing valve, aiming to solve or improve at least one of the above technical problems.

[0006] To achieve the above purpose, the present invention provides the following solutions: The present invention provides a high-quality and efficient machining device for the complex cavity of a superalloy pressure reducing valve, including:

[0007] A machine tool, on which a Z-axis guide rail and a driving component are installed; the driving component is used to drive the workpiece fixture to rotate;

[0008] A large-amplitude ultrasonic vibration drilling mechanism, which is slidably connected to the Z-axis guide rail through a tailstock moving assembly;

[0009] An X-axis guide rail, which is slidably connected to the Z-axis guide rail through a Z-axis moving assembly, and an X-axis moving assembly is slidably connected to the X-axis guide rail;

[0010] A two-dimensional ultrasonic vibration turning mechanism, which is installed on the X-axis moving assembly through a tool tip height precision adjustment mechanism;

[0011] A tool tip height precision detection mechanism, which is installed on the driving assembly and is used to detect the height of the two-dimensional ultrasonic vibration turning mechanism;

[0012] Wherein, the tailstock moving assembly, the X-axis moving assembly, the Z-axis moving assembly, the driving assembly, the tool tip height precision detection mechanism, the two-dimensional ultrasonic vibration turning mechanism, and the large-amplitude ultrasonic vibration drilling mechanism are all electrically connected to a main controller.

[0013] A high-quality and high-efficiency machining device for complex cavities of a superalloy pressure reducing valve according to the present invention, the two-dimensional ultrasonic vibration turning mechanism includes a housing and a longitudinal-bending vibration unit, the housing is installed on the tool tip height precision adjustment mechanism, and a second cooling air outlet, a second cooling air inlet and a second aviation plug are installed on the housing;

[0014] The longitudinal-bending vibration unit includes a compression bolt, a rear cover plate, a ring piezoelectric ceramic sheet, a first conductive copper sheet, a transducer base, a semi-ring piezoelectric ceramic sheet and a front cover plate;

[0015] The rear cover plate, the ring piezoelectric ceramic sheet and the first conductive copper sheet are installed on the transducer base through the compression bolt, and the semi-ring piezoelectric ceramic sheet, the first conductive copper sheet and the front cover plate are installed on the transducer base through a screw;

[0016] The transducer base is installed in the housing through a vibration unit fixing bolt, a blade installation groove is opened at the end of the front cover plate, a turning tool blade is installed on the blade installation groove, and the tool tip height precision detection mechanism is used to detect the height of the turning tool blade;

[0017] The annular piezoelectric ceramic sheet and the semi-annular piezoelectric ceramic sheet are connected to the first conductive copper sheet. The first conductive copper sheet is connected to the second aviation plug through a wire. The second aviation plug is connected to a dual-channel ultrasonic power supply through a data cable. The cooling air inlet is connected to a cooling air controller through an air pipe. The dual-channel ultrasonic power supply and the cooling air controller are electrically connected to the main controller.

[0018] A high-quality and high-efficiency machining device for complex cavities of a superalloy pressure reducing valve according to the present invention. The tip height precision adjustment mechanism includes:

[0019] A tool rest base, which is fixedly installed on the X-axis moving component through a tool rest locking bolt;

[0020] A dovetail guide rail, which is fixedly installed on the tool rest base through a guide rail locking bolt;

[0021] A tool rest block, which is installed on the tool rest base through a differential screw; a dovetail guide groove and a T-shaped groove are provided on the tool rest block. The dovetail guide groove is slidably connected to the dovetail guide rail, and the housing is installed on the tool rest block;

[0022] A T-shaped nut, which is placed in the T-shaped groove; the T-shaped nut is installed on the tool rest base through a tool height locking bolt.

[0023] A high-quality and high-efficiency machining device for complex cavities of a superalloy pressure reducing valve according to the present invention. The housing includes a housing base, a housing rear cover, and a housing upper cover;

[0024] The housing base is fixedly installed on the tool rest block through a tool fixing screw. The housing upper cover is fixedly installed on the housing base through an upper cover fixing bolt. The housing rear cover is fixedly installed on the housing base through a rear cover fixing bolt. The second cooling air outlet, the second cooling air inlet, and the second aviation plug are all installed on the housing rear cover; the transducer base is fixedly installed on the housing base through the vibration unit fixing bolt.

[0025] A high-amplitude ultrasonic vibration drilling mechanism according to the present invention for a high-quality and high-efficiency machining device for complex cavities of a superalloy pressure reducing valve includes:

[0026] The housing of the ultrasonic vibration drilling mechanism is mounted on the tailstock moving assembly; a first cooling air inlet, a first cooling air outlet, and a first aviation plug are installed on the housing of the ultrasonic vibration drilling mechanism; the second aviation plug is connected to a dual-channel ultrasonic power supply through a data cable, the first cooling air inlet is connected to a cooling air controller through an air pipe, and the dual-channel ultrasonic power supply and the cooling air controller are electrically connected to the main controller;

[0027] There is a flat-tail Morse taper shank, and the flat-tail Morse taper shank is installed on the housing of the ultrasonic vibration drilling mechanism through a locking screw;

[0028] A large-amplitude ultrasonic vibration unit, and the large-amplitude ultrasonic vibration unit is installed on the housing of the ultrasonic vibration drilling mechanism through a locking screw;

[0029] A composite ultrasonic drilling tool, and the composite ultrasonic drilling tool is installed on the large-amplitude ultrasonic vibration unit.

[0030] According to a high-quality and high-efficiency machining device for complex cavities of a superalloy pressure reducing valve provided by the present invention, the large-amplitude ultrasonic vibration unit includes a transducer, a first amplitude transformer, and a second amplitude transformer rod;

[0031] The transducer is installed on the first amplitude transformer through a locking bolt, the first amplitude transformer is installed on the second amplitude transformer rod through a screw rod, an ER collet and a locking nut are installed at the end of the second amplitude transformer rod, and the composite ultrasonic drilling tool is installed on the ER collet;

[0032] A second conductive copper sheet is connected to the transducer, and the second conductive copper sheet is connected to the first aviation plug through a wire.

[0033] According to a high-quality and high-efficiency machining device for complex cavities of a superalloy pressure reducing valve provided by the present invention, the tool tip height precision detection mechanism includes a tool tip height detection controller, a tool tip height detection sensor, and a tool tip height detection device support;

[0034] The tool tip height detection sensor is fixedly installed on the tool tip height detection device support, and the tool tip height detection device support is installed on the driving assembly;

[0035] The tool tip height detection sensor is electrically connected to the tool tip height detection controller through a signal wire, and the tool tip height detection controller is electrically connected to the main controller through a signal wire.

[0036] A high-quality and high-efficiency processing device for complex cavities of a superalloy pressure reducing valve according to the present invention, wherein the driving assembly includes a spindle seat installed on the machine tool, a spindle is installed on the spindle seat, the spindle seat is electrically connected to a spindle driver through a data cable, and the spindle driver is electrically connected to a main controller through a data cable.

[0037] The workpiece fixture is installed on the spindle through bolts, and the tip height detection device support is installed on the spindle seat through locking bolts.

[0038] A high-quality and high-efficiency processing device for complex cavities of a superalloy pressure reducing valve according to the present invention, wherein the tailstock movement assembly includes a tailstock slidably connected to the Z-axis guide rail, and the tailstock is electrically connected to a tailstock movement controller;

[0039] The X-axis movement assembly includes an X-axis carriage slidably connected to the X-axis guide rail, and the X-axis carriage is electrically connected to an X-axis movement controller;

[0040] The Z-axis movement assembly includes a Z-axis carriage slidably connected to the Z-axis guide rail, and the Z-axis carriage is electrically connected to a Z-axis movement controller;

[0041] The tailstock movement controller, the X-axis movement controller, and the Z-axis movement controller are all electrically connected to the main controller;

[0042] The housing of the ultrasonic vibration drilling mechanism is installed on the tailstock, the tool rest base is fixedly installed on the X-axis carriage through tool rest locking bolts, and the X-axis guide rail is installed on the Z-axis carriage.

[0043] The present invention also provides a method for high-quality and high-efficiency processing of complex cavities of a superalloy pressure reducing valve, including the following steps:

[0044] Step 1: Install and debug the large-amplitude ultrasonic vibration drilling mechanism, the tip height precision detection mechanism, the tip height precision adjustment mechanism, and the two-dimensional ultrasonic vibration turning mechanism respectively;

[0045] Step 2: Coarsely adjust the tip height. Control the X-axis movement assembly to move along the X-axis guide rail through the main controller, and control the Z-axis movement assembly to move along the Z-axis guide rail through the main controller, so that the tip of the two-dimensional ultrasonic vibration turning mechanism approaches the end face of the driving assembly. Adjust the tip position of the two-dimensional ultrasonic vibration turning mechanism through the tip height precision adjustment mechanism to complete the coarse adjustment of the tip height;

[0046] Step 3: Install and fix the turning specimen on the workpiece fixture, and align and clamp the turning specimen;

[0047] Step 4: Detect and record the height H0 from the rotation center of the driving component to the height precision detection mechanism of the tool tip. Control the two-dimensional ultrasonic vibration turning mechanism to work through the main controller. Control the X-axis moving component and the Z-axis moving component to move through the main controller to perform turning machining on the end face of the turning specimen. Observe and measure the diameter D0 of the cylindrical boss on the end face of the rod-shaped turning specimen through a microscope. Control the X-axis moving component and the Z-axis moving component to move through the main controller so that the tool tip of the two-dimensional ultrasonic vibration turning mechanism is within the measurement range of the height precision detection mechanism of the tool tip, obtain the distance L1 from the tool tip of the two-dimensional ultrasonic vibration turning mechanism to the height precision detection mechanism of the tool tip, and calculate the height from the rotation center of the driving component to the height precision detection mechanism of the tool tip as: H0 = L1 - D0 / 2, and record this H0;

[0048] Step 5: Fine-tune the tool tip height. Control the X-axis moving component and the Z-axis moving component to move through the main controller so that the tool tip of the two-dimensional ultrasonic vibration turning mechanism is within the measurement range of the height precision detection mechanism of the tool tip. Regulate the distance L2 from the tool tip of the two-dimensional ultrasonic vibration turning mechanism to the height precision detection mechanism of the tool tip through the height precision adjustment mechanism of the tool tip so that the height difference Δh between the tool tip of the two-dimensional ultrasonic vibration turning mechanism and the rotation center of the driving component is Δh = ∣L2 - H0∣ ≤ δ, where δ is the set maximum center height difference between the tool tip of the two-dimensional ultrasonic vibration turning mechanism and the rotation center of the driving component, and complete the fine-tuning of the tool tip height of the two-dimensional ultrasonic vibration turning mechanism;

[0049] Step 6: Install the part to be machined. Install and fix the part to be machined on the workpiece fixture, and perform alignment and clamping on the part to be machined;

[0050] Step 7: Rough machining of the complex cavity of the pressure reducing valve. Control the large-amplitude ultrasonic vibration drilling mechanism to work through the main controller. Control the tailstock moving component to move along the Z-axis guide rail through the main controller to complete the rough machining of the complex cavity of the pressure reducing valve;

[0051] Step 8: Finish machining of the complex cavity of the pressure reducing valve. Control the two-dimensional ultrasonic vibration turning mechanism to work through the main controller. Control the X-axis moving component and the Z-axis moving component to move through the main controller to complete the finish machining of the complex cavity of the pressure reducing valve;

[0052] Step 9: Machining completion. Replace the new tool after the tool is worn, and repeat the above Steps 5 to 8 to continue machining until all parts to be machined are machined.

[0053] The present invention discloses the following technical effects:

[0054] The present invention combines a large-amplitude ultrasonic vibration drilling mechanism and a two-dimensional ultrasonic vibration turning mechanism to solve the problems of complex processes, a large number of cutting tools, poor cooling conditions, severe tool wear, low machining efficiency, and high costs in the machining of complex cavity structures of superalloy pressure reducing valves, ensuring the dimensional accuracy and shape accuracy of the machining of complex cavities of superalloy pressure reducing valves, reducing the number of cutting tools and tool wear, improving the machining quality and efficiency of complex cavity structures of parts made of such materials, and reducing the machining cost;

[0055] The present invention utilizes the large-amplitude ultrasonic vibration to make the cutting tool and the workpiece material in the superalloy drilling process have intermittent contact, solves the problem that it is difficult for the cutting fluid to enter the cutting area, reduces the temperature and cutting force in the superalloy drilling, thereby providing favorable conditions for the use of composite drilling tools, significantly reducing the number of cutting tools required in the drilling of complex cavities, and improving the coaxiality accuracy of stepped holes, which helps to reduce the machining allowance of subsequent finish machining and improve the machining efficiency;

[0056] The present invention utilizes the two-dimensional ultrasonic vibration to make the cutting tool and the workpiece in the superalloy internal cavity turning undergo separated cutting, creates favorable conditions for the cutting fluid to enter the cutting area, reduces the cutting temperature and cutting force, reduces tool wear, improves the machining surface quality, realizes the machining of complex cavities of superalloy with the same cutting tool, improves the machining accuracy of the cavity, and reduces the number of cutting tools for cavity machining;

[0057] The present invention is convenient and fast to operate, has high precision, can meet the machining requirements of complex cavities of superalloy, and at the same time reduces the number of cutting tools and tool changing times for complex cavity machining. Through the tip height precision detection mechanism and the tip height precision adjustment mechanism, the tip height of the two-dimensional ultrasonic vibration turning mechanism can be conveniently and quickly adjusted, reducing the dependence on the operator's skills during the machining process, being easy to realize automation, and improving the machining precision and working efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required to be used in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0059] Figure 1 is a schematic structural diagram of the present invention;

[0060] Figure 2 is a schematic structural diagram of the large-amplitude ultrasonic vibration drilling mechanism in the present invention;

[0061] Figure 3 is Figure 2 a partial enlarged view of A in

[0062] Figure 4 It is a schematic structural diagram of the large-amplitude ultrasonic vibration unit in the present invention;

[0063] Figure 5 It is the schematic structure of the precise tip height adjustment mechanism in the present invention Figure Ⅰ ;

[0064] Figure 6 It is the schematic structure of the precise tip height adjustment mechanism in the present invention Figure Ⅱ ;

[0065] Figure 7 It is a schematic structural diagram of the two-dimensional ultrasonic vibration turning mechanism in the present invention;

[0066] Figure 8 is Figure 7 a partial enlarged view of B in;

[0067] Figure 9 It is a schematic structural diagram of the longitudinal-bending vibration unit in the present invention;

[0068] Figure 10 It is a schematic diagram of the complex cavity in the present invention;

[0069] Figure 11 It is a machining schematic diagram of the large-amplitude ultrasonic vibration drilling mechanism in the present invention;

[0070] Figure 12 It is a machining schematic diagram of the two-dimensional ultrasonic vibration turning mechanism in the present invention;

[0071] Figure 13 It is a flowchart of the processing method of the present invention.

[0072] Among them, 1. Machine tool; 2. Z-axis guide rail; 3. Tailstock; 4. Large-amplitude ultrasonic vibration drilling mechanism; 5. Z-axis pallet; 6. X-axis guide rail; 7. X-axis pallet; 8. Precision tool tip height adjustment mechanism; 9. Two-dimensional ultrasonic vibration turning mechanism; 10. Workpiece fixture; 11. Precision tool tip height detection mechanism; 12. Spindle seat; 13. Spindle; 41. Flat-tailed Morse taper shank; 42. Locking screw; 43. Ultrasonic vibration drilling mechanism housing; 44. First aviation plug; 45. First cooling air inlet; 46. First cooling air outlet; 47. Locking screw; 48. Large-amplitude ultrasonic vibration unit; 49. Composite ultrasonic drilling tool; 481. Locking bolt; 482. Transducer; 483. First-stage amplitude transformer; 484. Second-stage amplitude transformer; 485. Locking nut; 486. ER collet; 81. Tool holder block; 82. Tool fixing screw; 83. Tool holder base; 84. Differential screw; 85. T-slot; 86. T-nut; 87. Tool holder locking bolt; 88. Dovetail guide rail; 89. Guide rail locking bolt; 810. Dovetail guide groove; 811. Tool height locking bolt; 91. Housing base; 92. Rear cover plate of housing; 93. Second cooling air outlet; 94. Second cooling air inlet; 95. Second aviation plug; 96. Upper cover plate of housing; 97. Upper cover plate fixing bolt; 98. Longitudinal bending vibration unit; 99. Vibration unit fixing bolt; 910. Rear cover plate fixing bolt; 911. Turning tool insert; 981. Compression bolt; 982. Rear cover plate; 983. Annular piezoelectric ceramic sheet; 984. First conductive copper sheet; 985. Transducer base; 986. Semi-annular piezoelectric ceramic sheet; 987. Front cover plate. Detailed implementation manners

[0073] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without making creative efforts shall fall within the protection scope of the present invention.

[0074] To make the above objects, features, and advantages of the present invention more obvious and understandable, the present invention will be further described in detail below in conjunction with the accompanying drawings and specific implementation manners.

[0075] Referring to Figures 1 - 13 , the present invention provides a high-quality and high-efficiency processing device for complex cavities of a superalloy pressure reducing valve, including:

[0076] A machine tool 1, on which a Z-axis guide rail 2 and a driving assembly are installed; the driving assembly is used to drive the workpiece fixture 10 to rotate;

[0077] Large-amplitude ultrasonic vibration drilling mechanism 4, the large-amplitude ultrasonic vibration drilling mechanism 4 is slidably connected to the Z-axis guide rail 2 through the tailstock moving component;

[0078] X-axis guide rail 6, the X-axis guide rail 6 is slidably connected to the Z-axis guide rail 2 through the Z-axis moving component, and an X-axis moving component is slidably connected to the X-axis guide rail 6;

[0079] Two-dimensional ultrasonic vibration turning mechanism 9, the two-dimensional ultrasonic vibration turning mechanism 9 is installed on the X-axis moving component through the tool tip height precision adjustment mechanism 8;

[0080] Tool tip height precision detection mechanism 11, the tool tip height precision detection mechanism 11 is installed on the driving component and is used to detect the height of the two-dimensional ultrasonic vibration turning mechanism 9;

[0081] Among them, the tailstock moving component, the X-axis moving component, the Z-axis moving component, the driving component, the tool tip height precision detection mechanism 11, the two-dimensional ultrasonic vibration turning mechanism 9, and the large-amplitude ultrasonic vibration drilling mechanism 4 are all electrically connected to the main controller;

[0082] With such a setting, the present invention combines the large-amplitude ultrasonic vibration drilling mechanism 4 and the two-dimensional ultrasonic vibration turning mechanism 9 to solve the problems of complex process, large number of tools, poor cooling conditions, serious tool wear, low processing efficiency and high cost in the processing of the complex cavity structure of the superalloy pressure reducing valve, ensures the dimensional accuracy and shape accuracy of the complex cavity machining of the superalloy pressure reducing valve, reduces the number of tools and tool wear, improves the machining quality and efficiency of the complex cavity structure of this type of material parts, and reduces the processing cost;

[0083] The present invention uses the large-amplitude ultrasonic vibration effect to make the tool and the workpiece material in intermittent contact during the drilling of superalloy, solves the problem that the cutting fluid is difficult to enter the cutting area, reduces the temperature and cutting force during the drilling of superalloy, thus providing favorable conditions for the use of composite drilling tools, significantly reducing the number of tools required for drilling complex cavities, and improving the coaxiality accuracy of stepped holes, which helps to reduce the machining allowance of subsequent finishing and improve the machining efficiency;

[0084] The present invention uses the two-dimensional ultrasonic vibration effect to make the tool and the workpiece undergo separated cutting during the internal turning of superalloy, creates favorable conditions for the cutting fluid to enter the cutting area, reduces the cutting temperature and cutting force, reduces tool wear, improves the machining surface quality, realizes the use of the same tool to complete the machining of the complex cavity of superalloy, improves the cavity machining accuracy, and reduces the number of tools for cavity machining;

[0085] The present invention is convenient and fast to operate, with high precision, can meet the processing requirements of complex cavities of superalloys, and at the same time reduces the number of cutting tools and tool changing times for processing complex cavities. Through the tip height precision detection mechanism 11 and the tip height precision adjustment mechanism 8, the tip height adjustment of the two-dimensional ultrasonic vibration turning mechanism 9 can be conveniently and quickly realized, reducing the dependence on the operator's skills during the processing, being easy to automate, and improving the processing precision and work efficiency.

[0086] In a further optimized solution, the two-dimensional ultrasonic vibration turning mechanism 9 includes a housing and a longitudinal-bending vibration unit 98. The housing is installed on the tip height precision adjustment mechanism 8, and a second cooling air outlet 93, a second cooling air inlet 94, and a second aviation plug 95 are installed on the housing.

[0087] The longitudinal-bending vibration unit 98 includes a compression bolt 981, a rear cover plate 982, an annular piezoelectric ceramic sheet 983, a first conductive copper sheet 984, a transducer base 985, a semi-annular piezoelectric ceramic sheet 986, and a front cover plate 987.

[0088] The rear cover plate 982, the annular piezoelectric ceramic sheet 983, and the first conductive copper sheet 984 are installed on the transducer base 985 through the compression bolt 981, and the semi-annular piezoelectric ceramic sheet 986, the first conductive copper sheet 984, and the front cover plate 987 are installed on the transducer base 985 through a screw.

[0089] The transducer base 985 is installed in the housing through a vibration unit fixing bolt 99. A blade installation groove is provided at the end of the front cover plate 987, and a turning tool blade 911 is installed on the blade installation groove. The tip height precision detection mechanism 11 is used to detect the height of the turning tool blade 911.

[0090] The annular piezoelectric ceramic sheet 983 and the semi-annular piezoelectric ceramic sheet 986 are connected to the first conductive copper sheet 984. The first conductive copper sheet 984 is connected to the second aviation plug 95 through a wire. The second aviation plug 95 is connected to a dual-channel ultrasonic power supply through a data cable. The cooling air inlet is connected to a cooling air controller through an air pipe. The dual-channel ultrasonic power supply and the cooling air controller are electrically connected to the main controller.

[0091] In a further optimized solution, the tip height precision adjustment mechanism 8 includes:

[0092] A tool rest base 83, and the tool rest base 83 is fixedly installed on the X-axis moving component through a tool rest locking bolt 87.

[0093] A dovetail guide rail 88, and the dovetail guide rail 88 is fixedly installed on the tool rest base 83 through a guide rail locking bolt 89.

[0094] Tool rest block 81, the tool rest block 81 is installed on the tool rest base 83 through a differential screw 84; a dovetail guide groove 810 and a T-slot 85 are provided on the tool rest block 81, the dovetail guide groove 810 is slidably connected to a dovetail guide rail 88, and the housing is installed on the tool rest block 81;

[0095] T-nut 86, the T-nut 86 is placed in the T-slot 85; the T-nut 86 is installed on the tool rest base 83 through a tool height locking bolt 811.

[0096] Further optimized solution, the housing includes a housing base 91, a housing rear cover 92 and a housing upper cover 96;

[0097] The housing base 91 is fixedly installed on the tool rest block 81 through a tool fixing screw 82, the housing upper cover 96 is fixedly installed on the housing base 91 through an upper cover fixing bolt 97, the housing rear cover 92 is fixedly installed on the housing base 91 through a rear cover fixing bolt 910, and a second cooling air outlet 93, a second cooling air inlet 94 and a second aviation plug 95 are all installed on the housing rear cover 92; the transducer base 985 is fixedly installed on the housing base 91 through a vibration unit fixing bolt 99.

[0098] Further optimized solution, the large-amplitude ultrasonic vibration drilling mechanism 4 includes:

[0099] An ultrasonic vibration drilling mechanism housing 43, the ultrasonic vibration drilling mechanism housing 43 is installed on the tailstock moving assembly; a first cooling air inlet 45, a first cooling air outlet 46 and a first aviation plug 44 are installed on the ultrasonic vibration drilling mechanism housing 43; the second aviation plug 95 is connected to a dual-channel ultrasonic power supply through a data cable, the first cooling air inlet 45 is connected to a cooling air controller through an air pipe, and the dual-channel ultrasonic power supply and the cooling air controller are electrically connected to the main controller;

[0100] A flat-tail Morse taper shank 41, the flat-tail Morse taper shank 41 is installed on the ultrasonic vibration drilling mechanism housing 43 through a locking screw 42;

[0101] A large-amplitude ultrasonic vibration unit 48, the large-amplitude ultrasonic vibration unit 48 is installed on the ultrasonic vibration drilling mechanism housing 43 through a locking screw 42;

[0102] A composite ultrasonic drilling tool 49, the composite ultrasonic drilling tool 49 is installed on the large-amplitude ultrasonic vibration unit 48.

[0103] Further optimized solution, the large-amplitude ultrasonic vibration unit 48 includes a transducer 482, a first-stage amplitude transformer 483 and a second-stage amplitude transformer rod 484;

[0104] The transducer 482 is installed on the first-stage amplitude transformer 483 through a locking bolt 481. The first-stage amplitude transformer 483 is installed on the second-stage amplitude transformer rod 484 through a screw. An ER chuck 486 and a locking nut 485 are installed at the end of the second-stage amplitude transformer rod 484. The composite ultrasonic drilling tool 49 is installed on the ER chuck 486.

[0105] A second conductive copper sheet is connected to the transducer 482. The second conductive copper sheet is connected to the first aviation plug 44 through a wire.

[0106] In a further optimized solution, the tip height precision detection mechanism 11 includes a tip height detection controller, a tip height detection sensor, and a tip height detection device support.

[0107] The tip height detection sensor is fixedly installed on the tip height detection device support. The tip height detection device support is installed on the drive assembly.

[0108] The tip height detection sensor is electrically connected to the tip height detection controller through a signal wire. The tip height detection controller is electrically connected to the main controller through a signal wire.

[0109] In a further optimized solution, the drive assembly includes a spindle seat 12 installed on the machine tool 1. A spindle 13 is installed on the spindle seat 12. The spindle seat 12 is electrically connected to the spindle 13 driver through a data line. The spindle 13 driver is electrically connected to the main controller through a data line.

[0110] The workpiece fixture 10 is installed on the spindle 13 through bolts. The tip height detection device support is installed on the spindle seat 12 through a locking bolt 481.

[0111] In a further optimized solution, the tailstock movement assembly includes a tailstock 3 slidably connected to the Z-axis guide rail 2. The tailstock 3 is electrically connected to a tailstock 3 movement controller.

[0112] The X-axis movement assembly includes an X-axis support plate 7 slidably connected to the X-axis guide rail 6. The X-axis support plate 7 is electrically connected to an X-axis movement controller.

[0113] The Z-axis movement assembly includes a Z-axis support plate 5 slidably connected to the Z-axis guide rail 2. The Z-axis support plate 5 is electrically connected to a Z-axis movement controller.

[0114] The tailstock 3 movement controller, the X-axis movement controller, and the Z-axis movement controller are all electrically connected to the main controller.

[0115] The ultrasonic vibration drilling mechanism housing 43 is installed on the tailstock 3. The tool rest base 83 is fixedly installed on the X-axis support plate 7 through a tool rest locking bolt 87. The X-axis guide rail 6 is installed on the Z-axis support plate 5.

[0116] The present invention also provides a method for high-quality and high-efficiency machining of complex cavities of superalloy pressure reducing valves, including the following steps:

[0117] Step 1: Install and debug the large-amplitude ultrasonic vibration drilling mechanism 4, the tip height precision detection mechanism 11, the tip height precision adjustment mechanism 8, and the two-dimensional ultrasonic vibration turning mechanism 9 respectively;

[0118] Step 2: Coarsely adjust the tip height. Control the X-axis moving component to move along the X-axis guide rail 6 through the main controller, and control the Z-axis moving component to move along the Z-axis guide rail 2 through the main controller, so that the tip of the two-dimensional ultrasonic vibration turning mechanism 9 approaches the end face of the driving component. Adjust the tip position of the two-dimensional ultrasonic vibration turning mechanism 9 through the tip height precision adjustment mechanism 8 to complete the coarse adjustment of the tip height;

[0119] Step 3: Install and fix the turning specimen on the workpiece fixture 10, and align and clamp the turning specimen after alignment;

[0120] Step 4: Detect and record the height H0 from the rotation center of the driving component to the tip height precision detection mechanism 11. Control the two-dimensional ultrasonic vibration turning mechanism 9 to work through the main controller, control the X-axis moving component and the Z-axis moving component to move through the main controller, and perform turning machining on the end face of the turning specimen. Observe and measure the diameter D0 of the cylindrical boss on the end face of the rod-shaped turning specimen through a microscope; control the X-axis moving component and the Z-axis moving component to move through the main controller, so that the tip of the two-dimensional ultrasonic vibration turning mechanism 9 is within the measurement range of the tip height precision detection mechanism 11, obtain the distance L1 from the tip of the two-dimensional ultrasonic vibration turning mechanism 9 to the tip height precision detection mechanism 11, and calculate the height from the rotation center of the driving component to the tip height precision detection mechanism 11 as: H0 = L1 - D0 / 2, and record this H0;

[0121] Step 5: Fine-tune the tip height. Control the X-axis moving component and the Z-axis moving component to move through the main controller, so that the tip of the two-dimensional ultrasonic vibration turning mechanism 9 is within the measurement range of the tip height precision detection mechanism 11. Regulate the distance L2 from the tip of the two-dimensional ultrasonic vibration turning mechanism 9 to the tip height precision detection mechanism 11 through the tip height precision adjustment mechanism 8, so that the height difference Δh between the tip of the two-dimensional ultrasonic vibration turning mechanism 9 and the rotation center of the driving component is Δh = ∣L2 - H0∣ ≤ δ, where δ is the set maximum center height difference between the tip of the two-dimensional ultrasonic vibration turning mechanism 9 and the rotation center of the driving component. In this embodiment, the rotation center is the main shaft 13, and the fine adjustment of the tip height of the two-dimensional ultrasonic vibration turning mechanism 9 is completed;

[0122] Step 6: Install the part to be machined. Install and fix the part to be machined on the workpiece fixture 10, and align and clamp the part to be machined after alignment;

[0123] Step 7: Rough machining of the complex cavity of the pressure reducing valve. The main controller controls the operation of the large-amplitude ultrasonic vibration drilling mechanism 4, and controls the tailstock movement assembly to move along the Z-axis guide rail 2 to complete the rough machining of the complex cavity of the pressure reducing valve;

[0124] Step 8: Finish machining of the complex cavity of the pressure reducing valve. The main controller controls the operation of the two-dimensional ultrasonic vibration turning mechanism 9, and controls the X-axis movement assembly and the Z-axis movement assembly to move to complete the finish machining of the complex cavity of the pressure reducing valve;

[0125] Step 9: After the machining is completed, replace the new tool when the tool wears, and repeat the above Steps 5 to 8 to continue the machining until all the parts to be machined are completed.

[0126] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "longitudinal", "transverse", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present invention, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present invention.

[0127] Obviously, the above embodiments of the present invention are merely examples for clearly explaining the present invention, rather than limiting the implementation manners of the present invention. For those of ordinary skill in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the implementation manners here. Any modifications, equivalent replacements, and improvements made within the spirit and principle of the present invention shall be included in the protection scope of the claims of the present invention.

Claims

1. A high-quality and high-efficiency machining device for a complex cavity of a superalloy pressure reducing valve, characterized in that, Including: A machine tool (1) with a Z-axis guide rail (2) and a driving component installed thereon; the driving component is used to drive the workpiece fixture (10) to rotate; A large-amplitude ultrasonic vibration drilling mechanism (4), which is slidably connected to the Z-axis guide rail (2) through a tailstock moving component; An X-axis guide rail (6), which is slidably connected to the Z-axis guide rail (2) through a Z-axis moving component, and an X-axis moving component is slidably connected to the X-axis guide rail (6); A two-dimensional ultrasonic vibration turning mechanism (9), which is installed on the X-axis moving component through a tool tip height precision adjustment mechanism (8); A tool tip height precision detection mechanism (11), which is installed on the driving component and is used to detect the height of the two-dimensional ultrasonic vibration turning mechanism (9); Wherein, the tailstock moving component, the X-axis moving component, the Z-axis moving component, the driving component, the tool tip height precision detection mechanism (11), the two-dimensional ultrasonic vibration turning mechanism (9), and the large-amplitude ultrasonic vibration drilling mechanism (4) are all electrically connected to a main controller.

2. The high-temperature alloy pressure reducing valve complex cavity high-quality and high-efficiency machining device according to claim 1, characterized in that: The two-dimensional ultrasonic vibration turning mechanism (9) includes a housing and a longitudinal-bending vibration unit (98). The housing is installed on the tool tip height precision adjustment mechanism (8), and a second cooling air outlet (93), a second cooling air inlet (94), and a second aviation plug (95) are installed on the housing; The longitudinal-bending vibration unit (98) includes a compression bolt (981), a rear cover plate (982), an annular piezoelectric ceramic sheet (983), a first conductive copper sheet (984), a transducer base (985), a semi-annular piezoelectric ceramic sheet (986), and a front cover plate (987); The rear cover plate (982), the annular piezoelectric ceramic sheet (983), and the first conductive copper sheet (984) are installed on the transducer base (985) through the compression bolt (981), and the semi-annular piezoelectric ceramic sheet (986), the first conductive copper sheet (984), and the front cover plate (987) are installed on the transducer base (985) through a screw; The transducer base (985) is installed in the housing through a vibration unit fixing bolt (99). A blade installation groove is opened at the end of the front cover plate (987), and a turning tool blade (911) is installed on the blade installation groove. The tool tip height precision detection mechanism (11) is used to detect the height of the turning tool blade (911); The annular piezoelectric ceramic sheet (983) and the semi-annular piezoelectric ceramic sheet (986) are connected to the first conductive copper sheet (984). The first conductive copper sheet (984) is connected to the second aviation plug (95) through a wire. The second aviation plug (95) is connected to a dual-channel ultrasonic power supply through a data cable. The cooling air inlet is connected to a cooling air controller through an air pipe. The dual-channel ultrasonic power supply and the cooling air controller are electrically connected to the main controller.

3. The high-temperature alloy pressure reducing valve complex cavity high-quality and high-efficiency machining device according to claim 2, characterized in that: The highly precise cutting edge height adjustment mechanism (8) includes: A tool rest base (83), which is fixedly installed on the X-axis moving component through a tool rest locking bolt (87); A dovetail guide rail (88), which is fixedly installed on the tool rest base (83) through a guide rail locking bolt (89); A tool rest block (81), which is installed on the tool rest base (83) through a differential screw (84); a dovetail guiding groove (810) and a T-shaped groove (85) are formed on the tool rest block (81), the dovetail guiding groove (810) is slidably connected with the dovetail guide rail (88), and the housing is installed on the tool rest block (81); A T-shaped nut (86), which is placed in the T-shaped groove (85); the T-shaped nut (86) is installed on the tool rest base (83) through a tool height locking bolt (811).

4. The high-temperature alloy pressure reducing valve complex cavity high-quality and high-efficiency machining device according to claim 3, characterized in that: The housing includes a housing base (91), a housing rear cover plate (92) and a housing upper cover plate (96); The housing base (91) is fixedly installed on the tool rest block (81) through a tool fixing screw (82), the housing upper cover plate (96) is fixedly installed on the housing base (91) through an upper cover plate fixing bolt (97), the housing rear cover plate (92) is fixedly installed on the housing base (91) through a rear cover plate fixing bolt (910), a second cooling air outlet (93), a second cooling air inlet (94) and a second aviation plug (95) are all installed on the housing rear cover plate (92); a transducer base (985) is fixedly installed on the housing base (91) through a vibration unit fixing bolt (99).

5. The high-temperature alloy pressure reducing valve complex cavity high-quality and high-efficiency machining device according to claim 3, characterized in that: The large-amplitude ultrasonic vibration drilling mechanism (4) includes: An ultrasonic vibration drilling mechanism housing (43), which is installed on the tailstock moving component; a first cooling air inlet (45), a first cooling air outlet (46) and a first aviation plug (44) are installed on the ultrasonic vibration drilling mechanism housing (43); the second aviation plug (95) is connected to a dual-channel ultrasonic power supply through a data cable, the first cooling air inlet (45) is connected to a cooling air controller through an air pipe, and the dual-channel ultrasonic power supply and the cooling air controller are electrically connected to the main controller; A flat-tail Morse taper shank (41), which is installed on the ultrasonic vibration drilling mechanism housing (43) through a locking screw (42); A large-amplitude ultrasonic vibration unit (48), which is installed on the ultrasonic vibration drilling mechanism housing (43) through a locking screw (42); A composite ultrasonic drilling tool (49), which is installed on the large-amplitude ultrasonic vibration unit (48).

6. The high-temperature alloy pressure reducing valve complex cavity high-quality and high-efficiency machining device according to claim 5, characterized in that: The large-amplitude ultrasonic vibration unit (48) includes a transducer (482), a first-stage amplitude transformer (483) and a second-stage amplitude transformer rod (484); The transducer (482) is mounted on the first-stage amplitude changer (483) through a locking bolt (481). The first-stage amplitude changer (483) is mounted on the second-stage amplitude-changing rod (484) through a screw. An ER chuck (486) and a locking nut (485) are mounted at the end of the second-stage amplitude-changing rod (484). The composite ultrasonic drilling tool (49) is mounted on the ER chuck (486). A second conductive copper sheet is connected to the transducer (482). The second conductive copper sheet is connected to the first aviation plug (44) through a wire.

7. The high-temperature alloy pressure reducing valve complex cavity high-quality and high-efficiency machining device according to claim 1, characterized in that: The tip height precision detection mechanism (11) includes a tip height detection controller, a tip height detection sensor, and a tip height detection device support. The tip height detection sensor is fixedly mounted on the tip height detection device support. The tip height detection device support is mounted on the drive assembly. The tip height detection sensor is electrically connected to the tip height detection controller through a signal wire. The tip height detection controller is electrically connected to the main controller through a signal wire.

8. The high-temperature alloy pressure reducing valve complex cavity high-quality and high-efficiency machining device according to claim 7, characterized in that: The drive assembly includes a spindle base (12) mounted on the machine tool (1). A spindle (13) is mounted on the spindle base (12). The spindle base (12) is electrically connected to the spindle (13) driver through a data wire. The spindle (13) driver is electrically connected to the main controller through a data wire. The workpiece fixture (10) is mounted on the spindle (13) through bolts. The tip height detection device support is mounted on the spindle base (12) through a locking bolt (481).

9. The high-temperature alloy pressure reducing valve complex cavity high-quality and high-efficiency machining device according to claim 5, characterized in that: The tailstock movement assembly includes a tailstock (3) slidably connected to the Z-axis guide rail (2). The tailstock (3) is electrically connected to a tailstock (3) movement controller. The X-axis movement assembly includes an X-axis carriage (7) slidably connected to the X-axis guide rail (6). The X-axis carriage (7) is electrically connected to an X-axis movement controller. The Z-axis movement assembly includes a Z-axis carriage (5) slidably connected to the Z-axis guide rail (2). The Z-axis carriage (5) is electrically connected to a Z-axis movement controller. The tailstock (3) movement controller, the X-axis movement controller, and the Z-axis movement controller are all electrically connected to the main controller. The ultrasonic vibration drilling mechanism housing (43) is mounted on the tailstock (3). The tool rest base (83) is fixedly mounted on the X-axis carriage (7) through a tool rest locking bolt (87). The X-axis guide rail (6) is mounted on the Z-axis carriage (5).

10. A method for high-quality and high-efficiency machining of a complex cavity of a superalloy pressure reducing valve, based on the high-quality and high-efficiency machining device for the complex cavity of the superalloy pressure reducing valve according to any one of claims 1-9, characterized in that, Including the following steps: Step 1: Install and debug the large-amplitude ultrasonic vibration drilling mechanism (4), the tip height precision detection mechanism (11), the tip height precision adjustment mechanism (8), and the two-dimensional ultrasonic vibration turning mechanism (9) respectively. Step 2: Coarse adjustment of the tool tip height. Control the X-axis moving component to move along the X-axis guide rail (6) through the main controller, and control the Z-axis moving component to move along the Z-axis guide rail (2) through the main controller, so that the tool tip of the two-dimensional ultrasonic vibration turning mechanism (9) approaches the end face of the driving component. Adjust the tool tip position of the two-dimensional ultrasonic vibration turning mechanism (9) through the precise tool tip height adjustment mechanism (8) to complete the coarse adjustment of the tool tip height. Step 3: Install and fix the turning specimen on the workpiece fixture (10), and align and clamp the turning specimen after alignment. Step 4: Detect and record the height H0 from the rotation center of the driving component to the precise tool tip height detection mechanism (11). Control the two-dimensional ultrasonic vibration turning mechanism (9) to work through the main controller, control the X-axis moving component and the Z-axis moving component to move through the main controller, and perform turning processing on the end face of the turning specimen. Observe and measure the diameter D0 of the cylindrical boss on the end face of the rod-shaped turning specimen through a microscope. Control the X-axis moving component and the Z-axis moving component to move through the main controller, so that the tool tip of the two-dimensional ultrasonic vibration turning mechanism (9) is within the measurement range of the precise tool tip height detection mechanism (11), obtain the distance L1 from the tool tip of the two-dimensional ultrasonic vibration turning mechanism (9) to the precise tool tip height detection mechanism (11), and calculate the height from the rotation center of the driving component to the precise tool tip height detection mechanism (11) as: H0 = L1 - D0 / 2, and record this H0. Step 5: Fine adjustment of the tool tip height. Control the X-axis moving component and the Z-axis moving component to move through the main controller, so that the tool tip of the two-dimensional ultrasonic vibration turning mechanism (9) is within the measurement range of the precise tool tip height detection mechanism (11). Regulate the distance L2 from the tool tip of the two-dimensional ultrasonic vibration turning mechanism (9) to the precise tool tip height detection mechanism (11) through the precise tool tip height adjustment mechanism (8), so that the height difference Δh between the tool tip of the two-dimensional ultrasonic vibration turning mechanism (9) and the rotation center of the driving component is Δh = ∣L2 - H0∣ ≤ δ, where δ is the set maximum center height difference between the tool tip of the two-dimensional ultrasonic vibration turning mechanism (9) and the rotation center of the driving component, and complete the fine adjustment of the tool tip height of the two-dimensional ultrasonic vibration turning mechanism (9). Step 6: Install the part to be machined. Install and fix the part to be machined on the workpiece fixture (10), and align and clamp the part to be machined after alignment. Step 7: Rough machining of the complex cavity of the pressure reducing valve. Control the large-amplitude ultrasonic vibration drilling mechanism (4) to work through the main controller, and control the tailstock moving component to move along the Z-axis guide rail (2) through the main controller to complete the rough machining of the complex cavity of the pressure reducing valve. Step 8: Finish machining of the complex cavity of the pressure reducing valve. Control the two-dimensional ultrasonic vibration turning mechanism (9) to work through the main controller, and control the X-axis moving component and the Z-axis moving component to move through the main controller to complete the finish machining of the complex cavity of the pressure reducing valve. Step 9: Machining completed. Replace the new tool after the tool wears, and repeat the above steps 5 to 8 to continue machining until all parts to be machined are machined.

Images