A method for removing blade unbalance of a blisk

Abstract

The application provides a method for removing the unbalance of a blisk blade, which comprises the following steps: firstly, fixing the blisk on the workbench of a special part polishing and repairing turnover vehicle; secondly, determining the polishing blade number and polishing area according to the initial static unbalance measurement result of the part; thirdly, removing the specified blade unbalance and polishing the blade by adopting different specifications of sand belts through a specific polishing method; and finally, cleaning and packing the part. The application has the advantages that the problem of removing a large amount of unbalance to meet the requirement of high balance precision of the blisk is solved, the first-time qualified rate of the unbalance correction of the blisk is increased to more than 90%, the processing cycle is shortened by 60%, the blade shape and surface quality are good, and the processing efficiency and quality of the part are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of aero-engine technology, and in particular to a method for removing the imbalance of integral bladed disk blades, which is used to effectively remove the static imbalance of integral bladed disk parts, ensure the accuracy of the remaining imbalance of parts, and meet the balance requirements of rotor assembly. Background Technology

[0002] As a core component for structural innovation and technological breakthroughs in high-performance aero-engines, the integral bladed disk (IBD) eliminates the need for tenons, mortises, and locking devices used in traditional connection methods, reducing weight by 20%–30% and the number of parts by 50%. This simplifies the overall engine structure, making it more reliable. It also avoids airflow losses associated with tenons, improving aerodynamic and thermal performance during operation, resulting in a 5%–10% increase in engine efficiency. Integral bladed disk technology is a crucial means of achieving high thrust-to-weight ratios in aero-engines, representing the development direction of advanced aero-engine technology for high thrust-to-weight ratios, and has become an essential structure for high thrust-to-weight ratio aero-engines.

[0003] With increasingly stringent performance requirements for equipment and products in fields such as aerospace and energy, conventional manufacturing theories and methods that solely focus on ensuring geometric dimensions and tolerances are no longer sufficient to meet future development needs. The manufacturing of high-performance products urgently requires solutions, and the manufacturing philosophy must shift from prioritizing dimensional requirements to prioritizing performance requirements. Engine vibration is a key performance indicator for aero-engines, and vibration problems significantly hinder aero-engine development. Rotor imbalance is a major contributing factor to engine vibration. When an aero-engine operates at high speeds, the residual static imbalance of the rotor components has a significant impact on engine vibration. To control engine vibration caused by imbalance, it is necessary to improve balancing accuracy as much as possible and reduce the allowable residual static imbalance of the integral bladed disk. However, reducing the allowable residual static imbalance highlights the serious problems caused by excessive initial static imbalance of the components, requiring a large amount of imbalance removal to meet design requirements. Traditional methods of removing imbalance through machining on the disk are limited by the area to be removed, and the amount removed is no longer sufficient to meet the demand for large-scale removal. Blade polishing is an effective method for removing imbalance. However, because the blade profile of the integral bladed disk is a complex free-form surface with large blade twist angles and small blade spacing, polishing can easily lead to under-polishing or over-polishing, resulting in rework or dimensional deviations, making machining very difficult. Therefore, how to effectively correct imbalance while ensuring stable dimensional accuracy and structural integrity of the components has become an urgent problem to be solved. Summary of the Invention

[0004] The purpose of this invention is to propose a process for removing the imbalance of blades in an integral bladed disk, which can effectively solve the above-mentioned problems.

[0005] This invention provides a method for removing the imbalance of blades in an integral bladed disk. First, the integral bladed disk is fixed on the worktable of a special parts polishing and reversing machine. Second, the number of blades to be polished and the polishing area are determined based on the initial static imbalance measurement results of the parts. Then, through a rough polishing + semi-fine polishing + fine polishing scheme, different specifications of abrasive belts are used to complete the removal of the specified blade imbalance and the polishing operation through a specific polishing method. Finally, the parts are cleaned and packed.

[0006] A process for removing imbalance in blades of an integral bladed disk includes the following steps:

[0007] Step 1: Part clamping

[0008] ① Push the tipper to the appropriate position, lock the tipper wheels, and fix the tipper in place;

[0009] ② Adjust the tilting table to a horizontal position and insert the fixing pin to prevent the tilting table from tilting.

[0010] ③ Wipe the assembly surfaces clean, ensuring no residue remains;

[0011] ④ Use a crane and lifting equipment to lift the parts onto the assembly surface of the tilting vehicle and clamp them.

[0012] ⑤ Loosen the wheels of the tilting cart, push the cart to the designated position in the polishing work area, and lock the wheels to fix the tilting cart in place to prevent the cart body from sliding during processing.

[0013] Step 2: Determine the number of blades to be repaired and the repair area.

[0014] ① Confirm the number and location of the blades to be repaired.

[0015] Based on the initial unbalance weight G (in grams) and key locations marked on the surface of the parts, determine the number n and location of the unbalanced blades to be repaired (the number of blades is determined based on the actual weight to be removed, not exceeding 7 blades), and calculate the amount to be removed per blade f (in grams / blade). The repaired blades should be symmetrical about the initial unbalance key locations.

[0016] ② Determine the repair area

[0017] To prevent the risk of exceeding tolerances such as edge chipping at the leading and trailing edges of the blade due to manual polishing, the following principles should be followed when polishing areas with unbalanced amounts on the blade: do not polish within 10mm of the leading and trailing edges of the blade, do not polish within 30mm above the flow channel, and do not polish the top surface of the blade tip.

[0018] Step 3: Coarse polishing with A110 abrasive belt to remove excess material

[0019] ① Select a pyramidal abrasive belt with a particle size of A110 and correctly install it onto the metal support arm of the belt sander.

[0020] ②A110 abrasive belt polishing method

[0021] The sanding belt at the rubber pad of the metal support arm of the belt sander is the working part. Control the metal support arm of the belt sander so that the working plane of the sanding belt at the rubber pad contacts the surface to be polished on the blade base and blade back. The direction of the support arm forms a certain angle with the direction of the original machining marks on the blade. The angle is adjusted according to the actual machining situation. Control the metal support arm of the belt sander so that the working plane of the sanding belt at the rubber pad moves diagonally left and right along the blade base and blade back profile, evenly covering the machining marks of the A110 sanding belt. The polishing area of ​​the A110 sanding belt should be appropriately reduced according to the polishing range determined in step 2.

[0022] ③ Determine the number of passes for A110 sandpaper belt polishing

[0023] Completely processing all blade bases and blade backs of a single blade using the above polishing method is considered one pass of A110 abrasive belt polishing. When processing a part for the first time, after polishing all blades requiring polishing once with A110 abrasive belt, perform a static balance measurement on the part. Compare the unbalance values ​​before and after polishing to calculate the amount of material removed per pass of A110 abrasive belt polishing, e (g / pass). Therefore, calculate the number of passes of A110 abrasive belt polishing required for this part: M = [(GF) / n] / e = f / e, (0 ≤ F ≤ H).

[0024] G: Actual weight of initial imbalance, g; H: Theoretical maximum weight without initial imbalance, g

[0025] F: Remaining weight not measured in theoretical weight; gn: Number of blades repaired.

[0026] f: Removal amount per piece, g / piece e: Removal amount per pass of A110 sanding belt polishing, g / pass

[0027] The H value is given according to the design document, the F value is taken as F=0, and n is given according to the actual weight to be removed.

[0028] After the first processing of the part, the above conclusions can be recorded in the overall blade imbalance recording chart. The above data can be used to calculate the number of A110 sand belt polishing passes for subsequent batches of the part's blade imbalance process.

[0029] ④A110 abrasive belt subsequent polishing method

[0030] After determining the number of passes for A110 abrasive belt polishing, continue to complete the remaining passes according to the method in step 3-② above. When polishing the A110 abrasive belt in subsequent passes, the polishing direction should be at a certain angle to the previous polishing trajectory, and the A110 abrasive belt marks of the current processing should evenly cover the polishing area. There is no need to remove the previous A110 abrasive belt polishing marks, otherwise it may lead to the risk of excessive removal.

[0031] Step 4: Semi-finish polishing with A60 abrasive belt

[0032] ① Select a pyramidal abrasive belt with a particle size of A60 and correctly install it onto the metal support arm of the belt sander.

[0033] ②A60 abrasive belt polishing method

[0034] The sanding belt at the rubber pad of the metal support arm of the belt sander is the working part. Control the metal support arm to ensure the working plane of the sanding belt at the rubber pad contacts the A110 sanding belt polishing marks on the blade base and blade back. The direction of the support arm forms a certain angle with the direction of the A110 sanding belt polishing marks. This angle is adjusted according to the actual processing situation. Control the metal support arm to move the working plane of the sanding belt at the rubber pad significantly left and right along the blade base and blade back profile to remove the A110 sanding belt processing marks. The A60 sanding belt polishing area should include the A110 sanding belt area but be smaller than the maximum allowable polishing area.

[0035] Step 5: Semi-finish polishing with A20 abrasive belt

[0036] ① Select a pyramidal abrasive belt with a particle size of A20 and correctly install it onto the metal support arm of the belt sander.

[0037] ②A60 abrasive belt polishing method

[0038] The sanding belt at the rubber pad of the metal support arm of the belt sander is the working part. Control the metal support arm to ensure the working plane of the sanding belt at the rubber pad contacts the A60 sanding belt polishing marks on the blade base and blade back. The direction of the support arm forms a certain angle with the direction of the A60 sanding belt polishing marks. This angle is adjusted according to the actual processing conditions. Control the metal support arm to move the working plane of the sanding belt at the rubber pad significantly left and right along the blade base and blade back profile to remove the A60 sanding belt processing marks, ensuring the surface roughness of the polished area is no greater than Ra0.4. The A20 sanding belt polishing area should include the A60 sanding belt area, but not exceed the maximum allowable polishing area.

[0039] Step 6: Parts cleaning and packing

[0040] ① After completing the blade imbalance repair, carefully wipe the surface of the blades and flow channels with special wiping paper to remove dirt and excess material and avoid scratching.

[0041] ② Clean the special turnover box thoroughly, and hoist the cleaned parts from the tipper into the special turnover box for subsequent static balance measurement.

[0042] Advantages of this invention:

[0043] This invention provides a method for removing unbalance in integral bladed disks, which solves the problem that a large amount of unbalance needs to be removed in order to meet the high balance accuracy requirements of integral bladed disks. Moreover, the method of this invention increases the first-pass yield of unbalance correction of integral bladed disks to over 90%, shortens the processing cycle by 60%, and produces good blade shape and surface quality, which greatly improves the efficiency and quality of parts processing. Attached Figure Description

[0044] Figure 1 Schematic diagram of a parts repair and maintenance vehicle;

[0045] Figure 2 This is a schematic diagram of a belt sander;

[0046] Figure 3 This is a schematic diagram of the metal support arm of a belt sander;

[0047] Figure 4 Schematic diagram of the blade polishing area;

[0048] Figure 5 A schematic diagram of the first pass polishing angle for A110 abrasive belt;

[0049] Figure 6 Schematic diagram of the A110 abrasive belt polishing area;

[0050] Figure 7 This is a schematic diagram showing the direction of subsequent passes of polishing with A110 abrasive belt;

[0051] Figure 8 A schematic diagram showing the polishing area and direction of the A60 abrasive belt;

[0052] Figure 9 A schematic diagram showing the A20 abrasive belt polishing area and direction;

[0053] Figure 10 Schematic diagram of a special turnover box for whole leaf trays;

[0054] Figure 11 This is a diagram recording the unbalance of the blades thrown from the overall bladed disk. Detailed Implementation

[0055] The present invention will be further explained below with reference to specific implementation schemes, but it is not limited to the present invention. The structures, proportions, sizes, etc. shown in the accompanying drawings are only used to complement the content disclosed in the specification, so as to enable those skilled in the art to understand and read, and are not intended to limit the conditions under which the present invention can be implemented. Therefore, they have no substantial technical significance. Any modification of the structure, change of the proportion relationship or adjustment of the size, without affecting the effect and purpose that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0056] A process for removing imbalance in blades of an integral bladed disk includes the following steps:

[0057] Step 1: Part clamping

[0058] ① Push the tipper to a suitable position (with no obstacles around the work environment), lock the tipper wheels, and fix the tipper in place;

[0059] ② Adjust the tilting table to a horizontal position and insert the fixing pin to prevent the tilting table from tilting.

[0060] ③ Wipe the assembly surfaces clean, ensuring no residue remains;

[0061] ④ Use a crane and lifting tools (the lifting tools are special lifting tools) to lift the parts onto the assembly surface of the tipper and clamp the parts;

[0062] ⑤ Loosen the wheels of the tilting cart, push the cart to the designated position in the polishing work area, and lock the wheels to fix the tilting cart in place to prevent the cart body from sliding during processing.

[0063] Step 2: Determine the number of blades to be repaired and the repair area.

[0064] ① Confirm the number and location of the blades to be repaired.

[0065] Based on the initial unbalance weight G (in grams) and key locations marked on the surface of the parts, determine the number n and location of the unbalanced blades to be repaired (the number of blades is determined based on the actual weight to be removed, not exceeding 7 blades), and calculate the amount to be removed per blade f (in grams / blade). The repaired blades should be symmetrical about the initial unbalance key locations.

[0066] ② Determine the repair area

[0067] To prevent the risk of exceeding tolerances due to edge chipping at the leading and trailing edges of the blade caused by manual polishing, the following principles should be followed when polishing areas with uneven amounts on the blade: Do not polish within 10mm of the leading and trailing edges of the blade; do not polish within 30mm above the flow channel; do not polish the tip surface of the blade (see appendix). Figure 4 ).

[0068] Step 3: Coarse polishing with A110 abrasive belt to remove excess material

[0069] ① Select a pyramidal abrasive belt with an A110 grit size and correctly install it onto the metal support arm of the belt sander (see attached). Figure 2 , 3 ).

[0070] ②A110 abrasive belt polishing method

[0071] The sanding belt at the rubber pad of the metal support arm of the belt sander is the working part. Control the metal support arm to ensure that the working plane of the sanding belt at the rubber pad is in contact with the surface to be polished on the blade base and blade back. The direction of the support arm should form a certain angle with the direction of the original machining marks on the blade (see appendix). Figure 5 The included angle is adjusted according to the actual processing situation. The metal support arm of the belt sander is controlled to cause the working plane of the sanding belt at the rubber pad to move significantly left and right along the blade basin and blade back profile, evenly covering the A110 sanding belt processing marks. The A110 sanding belt polishing area should be appropriately reduced according to the polishing range determined in step 2 (see appendix). Figure 6 ).

[0072] ③ Determine the number of passes for A110 sandpaper belt polishing

[0073] Completely processing all blade bases and blade backs of a single blade using the above polishing method is considered one pass of A110 abrasive belt polishing. When processing a part for the first time, after polishing all blades requiring polishing once with A110 abrasive belt, perform a static balance measurement on the part. Compare the unbalance values ​​before and after polishing to calculate the amount of material removed per pass of A110 abrasive belt polishing, e (g / pass). Therefore, calculate the number of passes of A110 abrasive belt polishing required for this part: M = [(GF) / n] / e = f / e, (0 ≤ F ≤ H).

[0074] G: Actual weight of initial imbalance, g; H: Theoretical maximum weight without initial imbalance, g

[0075] F: Remaining weight not measured in theoretical weight; gn: Number of blades repaired.

[0076] f: Removal amount per piece, g / piece e: Removal amount per pass of A110 sanding belt polishing, g / pass

[0077] The H value is given according to the design document, the F value is taken as F=0, and n is given according to the actual weight to be removed.

[0078] After the initial machining of the parts, the conclusions drawn above can be recorded in the overall bladed disk blade imbalance recording chart (see attached). Figure 11 The above data can be used to calculate the number of polishing passes for A110 sand belts in subsequent batches of this part for the unbalanced blade polishing process.

[0079] ④A110 abrasive belt subsequent polishing method

[0080] After determining the number of passes for A110 abrasive belt polishing, continue with the remaining passes using the method described in step 3-② above. During subsequent A110 abrasive belt polishing, the polishing direction must form a certain angle with the previous polishing trajectory, ensuring that the A110 abrasive belt marks from this process evenly cover the polishing area (see attached). Figure 7 There is no need to remove the previous A110 sanding belt polishing marks, otherwise there is a risk of removing too much material.

[0081] Step 4: Semi-finish polishing with A60 abrasive belt

[0082] ① Select a pyramidal abrasive belt with a particle size of A60 and correctly install it onto the metal support arm of the belt sander.

[0083] ②A60 abrasive belt polishing method

[0084] The sanding belt at the rubber pad of the metal support arm of the belt sander is the working part. Control the metal support arm to bring the working plane of the sanding belt at the rubber pad into contact with the A110 sanding belt polishing marks on the blade base and blade back. The direction of the support arm should form a certain angle with the direction of the A110 sanding belt polishing marks. This angle should be adjusted according to the actual processing situation. Control the metal support arm to move the working plane of the sanding belt at the rubber pad significantly left and right along the blade base and blade back profile to remove the A110 sanding belt processing marks. The A60 sanding belt polishing area should include the A110 sanding belt area but be smaller than the maximum allowable polishing area (see appendix). Figure 8 ).

[0085] Step 5: Semi-finish polishing with A20 abrasive belt

[0086] ① Select a pyramidal abrasive belt with a particle size of A20 and correctly install it onto the metal support arm of the belt sander.

[0087] ②A60 abrasive belt polishing method

[0088] The sanding belt at the rubber pad of the metal support arm of the belt sander is the working part. Control the metal support arm to ensure the working plane of the sanding belt at the rubber pad contacts the A60 sanding belt polishing marks on the blade base and blade back. The direction of the support arm should form a certain angle with the direction of the A60 sanding belt polishing marks. This angle should be adjusted according to the actual processing conditions. Control the metal support arm to move the working plane of the sanding belt at the rubber pad significantly left and right along the blade base and blade back profile to remove the A60 sanding belt processing marks, ensuring the surface roughness of the polished area is no greater than Ra0.4. The A20 sanding belt polishing area should include the A60 sanding belt area but not exceed the maximum allowable polishing area (see appendix). Figure 9 ).

[0089] Step 6: Parts cleaning and packing

[0090] ① After completing the blade imbalance repair, carefully wipe the surface of the blades and flow channels with special wiping paper to remove dirt and excess material and avoid scratching.

[0091] ② Clean the special turnover box thoroughly (see attached document). Figure 10 The cleaned parts are then hoisted from the tipper into a special turnover box for subsequent static balance measurements.

[0092] Matters not covered in this invention are common knowledge.

[0093] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A process for removing imbalance in the blades of an integral bladed disk, characterized in that: The method for removing the imbalance of blades in an integral bladed disk includes the following steps: Step 1: Part clamping; ① Push the tipper to a suitable position, ensure there are no obstacles around the work environment, lock the tipper wheels to fix the tipper in place; ② Adjust the tilting table to a horizontal position and insert the fixing pin to prevent the tilting table from tilting. ③ Wipe the assembly surfaces clean, ensuring no residue remains; ④ Use a crane and lifting equipment to lift the parts onto the assembly surface of the tilting vehicle and clamp them. ⑤ Loosen the wheels of the tilting cart, push the cart to the designated position in the polishing work area, and lock the wheels to fix the tilting cart in place to prevent the cart body from sliding during processing; Step 2: Determine the number of blades to be repaired and the repair area; ① Confirm the number and location of the blades to be repaired; Based on the initial unbalance weight G and key location marked on the surface, confirm the number n and location of the unbalanced blades to be repaired. The number of blades is determined according to the actual weight to be removed, not exceeding 7 blades. Calculate the amount to be removed per blade, f, in g / blade. The repaired blades should be symmetrical about the initial unbalance key location. ② Determine the repair area; To prevent the risk of excessive edge trimming at the leading and trailing edges of the blade due to manual polishing, the following principles should be followed when polishing areas on the blade with unbalanced amounts: do not polish within 10mm of the leading and trailing edges of the blade, do not polish within 30mm above the flow channel, and do not polish the top surface of the blade tip. Step 3: Rough polishing with A110 abrasive belt to remove excess material; ① Select a pyramidal abrasive belt with a particle size of A110 and correctly install it onto the metal support arm of the belt sander; ②A110 abrasive belt polishing method; The sanding belt at the rubber pad of the metal support arm of the belt sander is the working part. Control the metal support arm of the belt sander so that the working plane of the sanding belt at the rubber pad is in contact with the surface to be polished on the blade basin and blade back. The direction of the support arm forms a certain angle with the direction of the original processing marks on the blade. The angle is adjusted according to the actual processing situation. Control the metal support arm of the belt sander so that the working plane of the sanding belt at the rubber pad moves diagonally left and right along the blade basin and blade back profile, evenly covering the A110 sanding belt processing marks. The A110 sanding belt polishing area should be appropriately reduced according to the polishing range determined in step 2. ③ Determine the number of passes required for A110 sandpaper polishing; Completely processing all blade bases and blade backs of a blade using the above polishing method is considered as one pass of A110 abrasive belt polishing. When processing a part for the first time, after polishing all blades requiring polishing once with A110 abrasive belt, perform a static balance measurement on the part and compare the unbalance values ​​before and after. The amount of material removed by one pass of A110 abrasive belt polishing, e, can be calculated, with the unit being g / pass. The number of passes of A110 abrasive belt polishing for this part can be calculated as M = [(GF) / n] / e = f / e, (0≤F≤H). G: Actual weight of initial imbalance, g; H: Theoretical maximum weight without initial imbalance, g F: Remaining weight not measured in theoretical weight; gn: Number of blades repaired. f: Removal amount per piece, g / piece e: Removal amount per pass of A110 sanding belt polishing, g / pass The H value is given according to the design documents, the F value is taken as F=0, and n is given according to the actual weight to be removed. After the first processing of the part, the above conclusions can be recorded in the overall blade imbalance recording chart. The above formula can be used to calculate the number of A110 sand belt polishing passes for subsequent batches of the part's blade imbalance process. ④ Subsequent polishing and repair methods for A110 abrasive belts; After determining the number of passes for A110 abrasive belt polishing, continue to complete the remaining passes according to the method in step 3-②. When polishing A110 abrasive belt in subsequent passes, the polishing direction must be at a certain angle to the previous polishing trajectory, and the A110 abrasive belt marks from this processing should evenly cover the polishing area. Step 4: Semi-finish polishing with A60 abrasive belt; ① Select a pyramidal abrasive belt with a particle size of A60 and correctly install it onto the metal support arm of the belt sander; ②A60 abrasive belt polishing method; The sanding belt at the rubber pad of the metal support arm of the belt sander is the working part. Control the metal support arm of the belt sander so that the working plane of the sanding belt at the rubber pad contacts the A110 sanding belt polishing marks on the blade base and blade back. The direction of the support arm forms a certain angle with the direction of the A110 sanding belt polishing marks. The angle is adjusted according to the actual processing situation. Control the metal support arm of the belt sander so that the working plane of the sanding belt at the rubber pad moves diagonally left and right along the blade base and blade back profile to remove the A110 sanding belt processing marks. The A60 sanding belt polishing area should include the A110 sanding belt area, but be smaller than the maximum allowable polishing area. Step 5: Semi-finish polishing with A20 abrasive belt; ① Select a pyramidal abrasive belt with a particle size of A20 and correctly install it onto the metal support arm of the belt sander; ②A60 abrasive belt polishing method; The sanding belt at the rubber pad of the metal support arm of the belt sander is the working part. Control the metal support arm of the belt sander so that the working plane of the sanding belt at the rubber pad contacts the A60 sanding belt polishing marks on the blade base and blade back. The direction of the support arm forms a certain angle with the direction of the A60 sanding belt polishing marks. The angle is adjusted according to the actual processing situation. Control the metal support arm of the belt sander so that the working plane of the sanding belt at the rubber pad moves diagonally left and right along the blade base and blade back profile to remove the A60 sanding belt processing marks and ensure that the surface roughness of the polished part is not greater than Ra0.

4. The A20 sanding belt polishing area should include the A60 sanding belt area and not be larger than the maximum allowable polishing area. Step 6: Parts cleaning and packing; ① After completing the blade imbalance repair, carefully wipe the surface of the blade and flow channel with special wiping paper to remove dirt and excess material and avoid scratching. ② Clean the special turnover box thoroughly, and hoist the cleaned parts from the tipper into the special turnover box for subsequent static balance measurement.

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