Friction welding blade clamping tool design method suitable for complex blade profile structure

Abstract

The invention relates to a friction welding blade clamping tool design method suitable for a complex blade profile structure, and the method comprises the steps: inputting a blade containing welding allowance and a blade disc three-dimensional model, and adopting a Parasolide format; establishing a projection plane by taking a blade clamping boss as a reference, and extracting blade structure contour parameters; the initial size A1 * B1 * C1 of the tool blank is determined; an inner cavity complementary with the blade profile is generated through Boolean subtraction; simulating a tool motion path in the blade-blade disc assembly and identifying an interference area; cutting the outer contour of the blank based on interference analysis to form an inclined avoiding groove; and iteratively optimizing the geometric boundaries of the inner and outer cavities of the tool by combining a preset movement track. And the tool structure is finally output, and the tool structure is suitable for the compressor / turbine bladed disc with narrow adjacent blade intervals and complex blade shapes. According to the method, through dynamic avoidance and parametric modeling design, the problem that the linear friction welding tool for the blisk of the aero-engine is prone to colliding and interfering with adjacent blades is effectively solved.

Description

Technical Field

[0001] The present invention relates to the technical field of blade clamping tooling for automated linear friction welding equipment, and in particular to a design method for a friction welding blade clamping tooling suitable for complex blade-shaped structures. Background Art

[0002] As a core component of the new generation of aircraft engines, blisks achieve weight reduction and significantly improve aerodynamic efficiency and reliability by eliminating the traditional tongue-and-groove connection structure. Currently, titanium alloy has become the mainstream material for blisks. Linear friction welding, due to its lack of fusion welding defects, narrow heat-affected zone, and ability to weld dissimilar materials, is widely used in the manufacture and repair of blisks on typical engines, such as the F119 and EJ200.

[0003] Compressor / turbine blisks often feature a three-dimensional, twisted design. The spacing between adjacent blades is often ≤10mm. Traditional clamping fixtures can easily interfere with the movement of adjacent blades within this confined space, resulting in reduced welding accuracy and even blade damage. Furthermore, when the blade profile changes, the original blade clamping fixture becomes unsuitable.

[0004] Existing patent CN202210879964.2 provides a blade fixing device for linear friction welding of an integral blisk, comprising a left clamp and a right clamp. The joint surface between the left and right clamps is provided with a clamping groove, and the blade is mounted within the clamping groove. The left clamp has a side surface with an outwardly protruding boss, which is used to strengthen the structural strength of the left clamp. The boss is provided with an inclined surface that matches the outer contour of the blade body of an adjacent blade on one side, and this inclined surface is used to avoid interference with the blade body movement of the adjacent blade on one side. The right clamp has a side surface with an inwardly recessed avoidance groove, which is used to avoid interference with the blade body movement of the adjacent blade on the other side. The left and right clamps are each provided with corresponding avoidance structures for adjacent blades, which effectively prevents interference between the clamps and the blade during linear friction welding. The boss also strengthens the structural strength of the left clamp, making the clamp both compact and structurally strong.

[0005] The avoidance structure of this existing patent fails to account for the dynamic interference path under high-frequency vibrations of linear friction welding. Its boss reinforcement is difficult to adapt to automated welding equipment for different blade profiles, and tooling must be redesigned when the blade profile changes. Furthermore, linear friction welding equipment is expensive, and weld failures caused by tooling interference can result in financial losses. Summary of the Invention

[0006] To solve the above technical problems, the present invention provides a method for designing a friction welding blade clamping tool suitable for complex blade structures; the specific technical solution is as follows: A method for designing a friction welding blade clamping fixture suitable for complex blade structures includes the following steps: Step 1: Input the 3D model of the blade to be welded; Step 2: Input the 3D model of the blade to be welded; Step 3: Import the blade model to be welded into the 3D modeling software, select the blade clamping boss to be welded as the reference, establish an equidistant reference plane, project the blade model contour onto the reference plane with the blade clamping boss as the reference, and obtain the projection angle of adjacent blade contours of the blade model to be welded on the equidistant section through sketch analysis and measurement; Step 4: Determine the initial size of the clamping tool blank according to the blade structure profile parameters; the initial blade clamping tool blank cube size is A1×B1×C1; Step 5: Superimpose the clamping tool blank, the blade model and the clamping tool blank through Boolean subtraction operation to generate the inner cavity contour of the clamping tool; Step 6: Assemble the blades to be welded inputted in step 1 and the blisks to be welded inputted in step 2 into an integral model in a 3D modeling software; Step 7: Based on the blade parameter model obtained in step 3, simulate the motion path of the clamping fixture and identify the motion rotation path of the interference area; Step 8: Load the fixture blank in the assembly environment, and cut the outer contour of the fixture blank to form an avoidance structure based on the interference area of ​​the fixture obtained in step 7; Step 9: Specify the motion trajectory of the clamping fixture relative to the blade to be welded, and optimize the inner and outer cavity structures of the clamping fixture; Step 10: Generate the overall structure of the clamping tooling; Step 11: Output the final clamping fixture design results.

[0007] The preferred solution of the friction welding blade clamping tooling design method suitable for complex blade structures is that in steps one and two, the three-dimensional model is a Parasolid format file.

[0008] The preferred embodiment of the friction welding blade clamping tooling design method suitable for complex blade-shaped structures is as follows: in step five, the clamping tooling blank and the blade to be welded are aligned according to the reference plane in the three-dimensional modeling software, and a Boolean subtraction operation is performed to generate an inner cavity contour complementary to the blade profile.

[0009] The preferred embodiment of the friction welding blade clamping tooling design method suitable for complex blade-shaped structures is that, in step eight, the outer cavity contour correction is achieved by avoiding the motion interference area between the clamping tooling and adjacent blades.

[0010] The preferred embodiment of the friction welding blade clamping tooling design method suitable for complex blade-shaped structures is that the avoidance structure is a cutting groove with an inclined angle; its position and size are determined according to the extreme position of the rotation path in step seven.

[0011] The preferred embodiment of the method for designing a friction welding blade clamping tooling suitable for complex blade-shaped structures is that, in step nine, the optimization includes iteratively adjusting the geometric boundaries of the inner and outer cavities of the tooling under a fixed motion trajectory.

[0012] The method for designing a friction welding blade clamping tooling suitable for complex blade structures is preferably applicable to compressor blades or turbine blades with complex three-dimensional torsion and narrow spacing between adjacent blades. Beneficial effects

[0013] This invention improves the efficiency of blade clamping tool design and development while reducing design costs. This design method has a certain degree of universality, and the clamping tool developed using this design method has a short cycle time, high efficiency, and cost savings. The blade clamping tool developed using this design method can effectively avoid motion interference with the blades on both sides, preventing blade damage and cost waste caused by motion collisions. It is expected to save 20% of costs and has high economic value. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 Schematic diagram of the profile parameters of the blade to be welded; Figure 2 This is a schematic diagram of the clamping tooling scene; Figure 3 This is a schematic diagram of the blade clamping tooling assembly; Figure 4 This is a general design flow chart for blade clamping fixtures.

[0015] In the figure: 1-blade to be welded, 2-reference plane, 3-projection angle of adjacent blade contours on equidistant sections, 4-clamping fixture, 5-avoidance structure, 6-left half of the clamping fixture, 7-right half of the clamping fixture. DETAILED DESCRIPTION

[0016] The following is combined with Figure 1-4 The present invention is described in detail, but the protection scope of the present invention is not limited by the accompanying drawings.

[0017] Example 1

[0018] A method for designing a friction welding blade clamping fixture suitable for complex blade structures includes the following steps: Step 1: Model processing before welding: Use 3D CAD software to complete the drawing of the blade model's residual model before welding, design the welding joint, etc., select the 3D model of the blade to be linear friction welded, and output the Parasolid format file; Step 2: Model processing before welding: Use computer 3D modeling software to complete the drawing of the residual model of the blade disk model before welding, design the welding joint, etc., select the 3D model of the blade disk to be linear friction welded, and output the Parasolid format file; Step 3: Select the Parasolid format file blade 3D model output in step 2, create the maximum envelope, add analysis and measurement to the 3D modeling software, obtain the maximum size of the blade to be welded, select the blade clamping boss to be welded as the reference, establish the equidistant reference plane 2 based on the clamping boss, obtain the blade contour on the reference plane 2, project the contour to the reference plane 2 based on the blade clamping boss, analyze and measure the projection angle 3 of the adjacent blade contours of the blade 1 to be welded on the equidistant section in the sketch environment, and obtain the model parameters of the blade 1 to be welded as follows Figure 1 As shown; Step 4: Based on the measurement results obtained in step 3, preliminarily select the blade clamping fixture blank and complete the blank entity drawing of the blade clamping fixture 4. The blank size A1×B1×C1 is determined by the blade profile; Step 5: Select the blade reference plane in the 3D modeling software, align the clamping tool blank and the blade according to the reference plane, select the Boolean subtraction command, select the Boolean "subtraction" operation rule, and perform the Boolean subtraction operation on the clamping tool blank and the blade. After the operation, the inner cavity contour of the clamping tool that is complementary to the blade profile is obtained; Step 6: Assemble the blades to be welded inputted in step 1 and the blisks to be welded inputted in step 2 into an integral model in a 3D modeling software; Step 7: Based on the blade parameter model obtained in step 3, simulate the motion path of the clamping fixture and identify the motion rotation path of the interference area; Step 8: Load the fixture blank in the assembly environment, and cut the outer contour of the fixture blank to form an avoidance structure 5 according to the interference area of ​​the fixture obtained in step 7; Step 9: Preliminarily formulate the motion trajectory of the blade clamping tool relative to the blade disk; optimize the geometric boundaries of the inner and outer cavities of the blade tool under the fixed motion trajectory of the clamping tool relative to the blade disk obtained in step 9; Step 10: Generate the overall structure of the clamping tool; the tool consists of the left half 6 of the clamping tool and the right half 7 of the clamping tool; Step 11: Output the final clamping fixture 4 design results. The design process is as follows: Figure 4 shown.

Claims

1. A method for designing a friction welding blade clamping fixture suitable for complex blade structures, characterized by: The following steps are involved: Step 1: Input the 3D model of the blade to be welded; Step 2: Input the 3D model of the blade to be welded; Step 3: Import the blade model to be welded into the 3D modeling software, select the blade clamping boss to be welded as the reference, establish an equidistant reference plane, project the blade model contour onto the reference plane with the blade clamping boss as the reference, and obtain the projection angle of adjacent blade contours of the blade model to be welded on the equidistant section through sketch analysis and measurement; Step 4: Determine the initial size of the clamping tool blank based on the blade structure profile parameters; The cube size of the blank held by the primary blade clamping fixture is A1×B1×C1; Step 5: Superimpose the clamping tool blank, the blade model and the clamping tool blank through Boolean subtraction operation to generate the inner cavity contour of the clamping tool; Step 6: Assemble the blades to be welded inputted in step 1 and the blisks to be welded inputted in step 2 into an integral model in a 3D modeling software; Step 7: Based on the blade parameter model obtained in step 3, simulate the motion path of the clamping fixture and identify the motion rotation path of the interference area; Step 8: Load the fixture blank in the assembly environment, and cut the outer contour of the fixture blank to form an avoidance structure based on the interference area of ​​the fixture obtained in step 7; Step 9: Specify the motion trajectory of the clamping fixture relative to the blade to be welded, and optimize the inner and outer cavity structures of the clamping fixture; Step 10: Generate the overall structure of the clamping tooling; Step 11: Output the final clamping fixture design results.

2. The method for designing a friction welding blade clamping fixture suitable for complex blade structures according to claim 1, characterized in that: In step 1 and step 2, the three-dimensional model is a Parasolid format file.

3. The method for designing a friction welding blade clamping fixture suitable for complex blade structures according to claim 1, characterized in that: In step five, the clamping tool blank and the blade to be welded are aligned according to the reference plane in the 3D modeling software, and a Boolean subtraction operation is performed to generate an inner cavity contour that is complementary to the blade profile.

4. The method for designing a friction welding blade clamping fixture suitable for complex blade structures according to claim 1, characterized in that: In step eight, the outer cavity contour correction is achieved by avoiding the motion interference area between the clamping fixture and the adjacent blades.

5. The method for designing a friction welding blade clamping fixture suitable for complex blade structures according to claim 1, characterized in that: The avoidance structure is a cutting groove with an inclined angle; its position and size are determined according to the limit position of the rotation path in step seven.

6. The method for designing a friction welding blade clamping fixture suitable for complex blade structures according to claim 1, characterized in that: In step nine, the optimization includes iteratively adjusting the geometric boundaries of the inner and outer cavities of the tooling under a fixed motion trajectory.

7. The method for designing a friction welding blade clamping fixture suitable for complex blade structures according to claim 1, characterized in that: The method is applicable to compressor / turbine blade disks with complex three-dimensional torsion and narrow intervals between adjacent blades.

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