High-efficiency low-deformation processing method suitable for aero blade disc and aero engine

Abstract

The application discloses a kind of high-efficiency low-deformation processing methods suitable for aero blade disc and aero-engine, comprising the following steps: S1: based on ball head spiral cone milling cutter construction cutting force model, and carry out cutting test, to determine the cutting force coefficient;S2: by using special software to carry out numerical control simulation to milling cutter, to determine the processing path according to the maximum principle of cutting system stiffness, then based on the processing path, the cutting area and cutting edge length are extracted by special software, to calculate the real-time cutting force in the processing path, then the finite element model of blade disc is constructed, to carry out transient mechanics analysis in blade surface coordinate system, when cutting deformation exceeds the set range, adjust the cutting parameters and the inclination angle of workbench, determine the parameter interval I of feed rate and cutting depth;S3: carry out modal test to obtain modal parameters, then calculate the parameter interval of different processing parameters and spindle speed in sequence by using calculation software, obtain effective processing parameters.

Description

Technical Field

[0001] This invention relates to the field of aero-engine parts processing technology, and in particular, to a high-efficiency, low-deformation processing method suitable for aero-engine blade disks. Furthermore, it also relates to an aero-engine. Background Technology

[0002] Bladed disks, composed of numerous blades, are key components of aero-engines. Their performance is closely related to factors such as cutting deformation and surface profile. Among these, cutting deformation is closely related to cutting force. Predicting cutting force and optimizing milling process parameters to improve the performance of the blade disk is a common technique. Theoretically, the finishing of blade disks typically uses ball-end spiral bevel milling cutters. When constructing and identifying the cutting force coefficient, it is necessary to prepare a test tool with a consistent cutting edge of the ball-end spiral bevel milling cutter and conduct cutting force tests under different combinations of process parameters. Then, the cutting force coefficient is obtained using the least squares method. This coefficient is then used to predict the cutting force, thereby optimizing the milling process parameters of the blade disk and improving its performance.

[0003] However, in the process of identifying the cutting force coefficient, the complex geometry of the ball-end spiral bevel end mill, especially with a rake angle of no less than 35° and a helix angle reaching 45°, leads to a discrepancy between the rake angle and helix angle of the cutting edge and those of traditional turning tools. Furthermore, in actual manufacturing, the cutting edge of the spiral bevel end mill may deviate. Traditional methods typically assume an ideal tool geometry, resulting in significant differences between the tool geometry used in traditional theoretical models and experimental tests and the actual tool. This leads to a large deviation between the cutting force coefficient and the actual cutting force coefficient during machining. When predicting cutting forces and optimizing process parameters, the deviation in the cutting force coefficient prevents transmission optimization methods from accurately predicting the actual cutting force. Moreover, the optimization process does not fully consider the influence of cutting parameters on cutting deformation, resulting in poor optimization effects and discrepancies between the optimization results and actual machining results. Consequently, the machining accuracy and performance of the blade disk are difficult to improve effectively. Summary of the Invention

[0004] This invention provides an efficient and low-deformation machining method and aero-engine suitable for aircraft blade disks, in order to solve the existing technical problems of large deviation of cutting force coefficient, low accuracy of cutting force prediction, poor optimization effect of process parameters, and difficulty in effectively improving the machining accuracy and performance of blade disks.

[0005] According to one aspect of the present invention, a high-efficiency, low-deformation machining method suitable for aircraft blade disks is provided, comprising the following steps: S1: Constructing a cutting force model based on a ball-end spiral conical end mill, and conducting cutting tests using the ball-end spiral conical end mill as the machining tool, thereby determining the cutting force coefficient in the cutting force model; S2: Performing CNC simulation of the ball-end spiral conical end mill using dedicated software, determining the machining path based on the principle of maximizing the stiffness of the cutting system, and constructing a blade surface coordinate system based on the blade disk surface, then extracting the cutting area and cutting edge length using dedicated software based on the machining path, thereby calculating the real-time cutting force in the machining path, and then constructing a finite element model of the blade disk. The meta-model is used to conduct transient mechanical analysis in the blade surface coordinate system. Based on the machining path and real-time cutting force, the cutting component force that applies load to the blades in the blade disk is determined. The stiffness of the blades in the blade disk in the direction of the cutting component force is calculated to determine whether the cutting deformation is within the set range. When the cutting deformation exceeds the set range, the cutting parameters at the current machining deformation point and the tilt angle of the worktable are adjusted according to the adjustment strategy to determine the parameter interval I of feed rate and cutting depth; S3: Modal testing is carried out on the blades of the blade disk to obtain modal parameters. Then, the parameter intervals of different machining parameters and spindle speed are calculated sequentially using calculation software. Finally, the effective machining parameters are obtained through multiple parameter intervals.

[0006] As a further improvement to the above technical solution:

[0007] Furthermore, in step S1, the calculation equation for the cutting force model is:

[0008]

[0009] Wherein, the tangential, radial, and normal directions are set as the x, y, and z directions, respectively; the tangential direction is the tool feed direction; the radial direction is perpendicular to the rotation axis; and the normal direction is perpendicular to the tool feed direction. F x F y and F z Let x, y, and z be the cutting forces in the x, y, and z directions, respectively; l be the cutting edge length; b be the cutting width; θ be the angle between the axis of the ball-end spiral conical milling cutter and the surface to be machined on the blade disk; and k be the cutting force. xl k yl and k zl The cutting force coefficients, k, represent the cutting edge lengths in the x, y, and z directions, respectively. xs k ys and k zs These are the cutting force coefficients for the cutting areas in the x, y, and z directions, respectively.

[0010] Further, in step S2, the adjustment strategy is as follows: S21: Determine the cutting force component at the current machining deformation point through the cutting force model, and analyze the influence of the cutting force component on the cutting deformation, wherein the cutting force component includes Fx F y and F z S22: Calculate the amount of cutting deformation at the current machining deformation location in the direction of the cutting force component, so as to construct the correlation function between the cutting parameters and the total cutting deformation. Then, perform sensitivity analysis on the cutting parameters through the correlation function to determine the cutting parameters to be adjusted first. At the same time, adjust the tilt angle of the worktable according to the magnitude of the cutting force component.

[0011] Furthermore, the process of constructing the correlation function is as follows: S221, based on the cutting force model, determine the functional relationship between the cutting force and the cutting parameters; S222, based on the relationship between the cutting force and the cutting deformation, establish the influence model of the cutting component force on the cutting deformation; S223, combine the cutting force model and the influence model to obtain the correlation function of the cutting parameters on the total cutting deformation.

[0012] Furthermore, the correlation function is:

[0013]

[0014] Among them, D total Let p be the total cutting deformation, m be the cutting parameter vector, and K be the material parameter vector. iF K is the cutting force coefficient for the cutting edge length. iA k is the cutting force coefficient of the cutting area. i For directional stiffness.

[0015] Furthermore, the adjustment strategy also includes adjusting the tool feed direction and adjusting the tool angle.

[0016] Furthermore, in step S3, the modal testing of the blade disk blade to obtain modal parameters specifically includes the following steps: dividing the blade disk blade into N regions with equal area, marking the connection points of each region, and conducting modal testing on each connection point to obtain the modal parameters of each connection point.

[0017] Further, in step S3, the calculation of the parameter ranges for different machining parameters and spindle speeds using calculation software includes the following steps: First, the calculation software is used to calculate the stable machining region under weak blade stiffness. Then, the cutting force coefficient and modal parameters of each connection point are input into the calculation software to calculate the parameter range II of axial cutting depth and spindle speed in the blade surface coordinate system. Second, based on the mapping law between the machining path, the tilt angle of the worktable, and the blade surface coordinate system, the correlation law between the axial cutting depth and radial cutting depth in the actual machining process and the axial cutting depth in the blade surface coordinate system is established to obtain the parameter range III of cutting parameters and spindle speed in the actual machining process. Third, the calculation software is used to calculate the stable machining region under weak tool stiffness. Then, the cutting force coefficient and modal parameters of each connection point are input into the calculation software to calculate the parameter range IV of axial cutting depth and spindle speed in the tool coordinate system.

[0018] Furthermore, the specific steps for obtaining the effective machining parameter domain V through the intersection of multiple parameter intervals are as follows: obtain the machining parameter domain V through the intersection of parameter intervals II-IV, select effective machining parameters from the machining parameter domain V, and combine with parameter interval I to determine the spindle speed within the machining parameter domain V.

[0019] According to another aspect of the present invention, an aero-engine is also provided, including a blade disk, wherein the blade disk is processed using the above-described efficient and low-deformation machining method suitable for aero-engine blade disks.

[0020] The present invention has the following beneficial effects:

[0021] This invention provides a high-efficiency, low-deformation machining method for aero-blade disks. It constructs a cutting force model based on a ball-end spiral conical milling cutter and conducts cutting experiments using the cutter as the machining tool to determine the cutting force coefficient in the model. The ball-end spiral conical milling cutter serves as the actual machining tool for the blade disk milling. The identification of the cutting force coefficient closely reflects actual machining conditions, ensuring accuracy and reliability. By employing specialized software for CNC simulation of the ball-end spiral conical milling cutter, the machining path is determined based on the principle of maximizing the stiffness of the cutting system. A blade surface coordinate system is constructed based on the blade disk's curved surface. Then, based on the machining path, the cutting area and cutting edge length are extracted using specialized software to calculate the real-time cutting force along the machining path, improving the prediction accuracy of the cutting force. A finite element model of the blade disk is then constructed to conduct transient mechanical analysis in the blade surface coordinate system. Based on the machining path and real-time cutting force, the cutting component force applying the load to the blades in the blade disk is determined. The stiffness of the blades in the blade disk in the direction of the cutting component force is calculated to determine whether the cutting deformation is within a set range. If the cutting deformation exceeds the set range, an adjustment strategy is implemented. By adjusting the cutting parameters at the current machining deformation point and the tilt angle of the worktable, the parameter range I for feed rate and depth of cut is determined. This fully considers the influence of cutting parameters and the tilt angle of the worktable on cutting force, and consequently on cutting deformation, achieving an optimal balance between cutting force and cutting deformation, thus improving the optimization effect of process parameters. Modal testing is conducted on the blades of the blade disk to obtain modal parameters. Then, calculation software is used to sequentially calculate the parameter ranges for different machining parameters and spindle speeds. Effective machining parameters are then obtained through multiple parameter ranges. This allows for efficient and low-deformation machining of the blade disk using these effective machining parameters, effectively improving the machining accuracy and performance of the blade disk. This solution uses a ball-end spiral conical milling cutter to determine the cutting force coefficient, ensuring the coefficient closely matches the actual machining conditions and improving the prediction accuracy of cutting force. Furthermore, by adjusting the cutting parameters, the relationship between cutting force and cutting deformation is optimized. Compared to existing technologies, this solution exhibits a smaller deviation in the cutting force coefficient, higher prediction accuracy of cutting force, and better optimization effect of process parameters, effectively improving the machining accuracy and performance of the blade disk. It is highly practical and suitable for widespread promotion and application.

[0022] In addition to the objectives, features, and advantages described above, the present invention has other objectives, features, and advantages. The invention will now be described in further detail with reference to the figures. Attached Figure Description

[0023] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0024] Figure 1This is a flowchart illustrating the steps of a preferred embodiment of the present invention for a high-efficiency, low-deformation machining method for aircraft blade disks. Detailed Implementation

[0025] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings. However, the present invention can be implemented in many different ways as defined and covered below.

[0026] like Figure 1 As shown, the efficient and low-deformation machining method for aerospace blade disks in this embodiment includes the following steps: S1: Constructing a cutting force model based on a ball-end spiral conical milling cutter and conducting cutting tests using the ball-end spiral conical milling cutter as the machining tool to determine the cutting force coefficient in the cutting force model; S2: Performing CNC simulation of the ball-end spiral conical milling cutter using dedicated software to determine the machining path based on the principle of maximizing the stiffness of the cutting system, constructing a blade surface coordinate system based on the blade disk surface, and then extracting the cutting area and cutting edge length using dedicated software based on the machining path to calculate the real-time cutting force in the machining path, and finally constructing a finite element model of the blade disk. Transient mechanical analysis is performed in the blade surface coordinate system. Based on the machining path and real-time cutting force, the cutting component force that applies load to the blades in the blade disk is determined. The stiffness of the blades in the blade disk in the direction of the cutting component force is calculated to determine whether the cutting deformation is within the set range. When the cutting deformation exceeds the set range, the cutting parameters at the current machining deformation point and the tilt angle of the worktable are adjusted according to the adjustment strategy to determine the parameter range I of feed rate and cutting depth. S3: Modal testing is performed on the blades of the blade disk to obtain modal parameters. Then, the parameter range of different machining parameters and spindle speed is calculated sequentially using calculation software. Finally, the effective machining parameters are obtained through multiple parameter ranges.

[0027] like Figure 1As shown, specifically, the efficient and low-deformation machining method for aircraft blade disks of the present invention constructs a cutting force model based on a ball-end spiral conical milling cutter and conducts cutting tests using the ball-end spiral conical milling cutter as the machining tool to determine the cutting force coefficient in the cutting force model. The ball-end spiral conical milling cutter is the actual machining tool for milling the blade disk. The identification of the cutting force coefficient is close to the actual machining situation, and the cutting force coefficient is accurate and reliable. By using dedicated software to perform CNC simulation of the ball-end spiral conical milling cutter, the machining path is determined according to the principle of maximizing the stiffness of the cutting system. A blade surface coordinate system is constructed based on the blade disk surface. Based on the machining path, the cutting area and cutting edge length are extracted using dedicated software to calculate the real-time cutting force in the machining path, thereby improving the prediction accuracy of the cutting force. Then, a finite element model of the blade disk is constructed to conduct transient mechanical analysis in the blade surface coordinate system. Based on the machining path and real-time cutting force, the cutting component force that applies the load to the blade in the blade disk is determined, and the stiffness of the blade in the blade disk in the direction of the cutting component force is calculated to determine whether the cutting deformation is within the set range. When the cutting deformation exceeds the set range, an adjustment strategy is adopted. By slightly adjusting the cutting parameters and the tilt angle of the worktable at the current machining deformation point, and simultaneously determining the parameter range I for feed rate and depth of cut, the influence of cutting parameters and the tilt angle of the worktable on cutting force, and consequently on cutting deformation, is fully considered. This achieves an optimal balance between cutting force and cutting deformation, improving the optimization effect of process parameters. Modal testing is conducted on the blades of the blade disk to obtain modal parameters. Then, calculation software is used to sequentially calculate the parameter ranges for different machining parameters and spindle speeds. Effective machining parameters are then obtained through multiple parameter ranges. This allows for efficient and low-deformation machining of the blade disk using effective machining parameters, effectively improving the machining accuracy and performance of the blade disk. This solution uses a ball-end spiral conical milling cutter to determine the cutting force coefficient, ensuring that the cutting force coefficient closely matches the actual machining conditions, improving the prediction accuracy of cutting force. By adjusting the cutting parameters, the relationship between cutting force and cutting deformation is optimized. Compared with existing technologies, this solution has a smaller deviation in cutting force coefficient, higher prediction accuracy of cutting force, and better optimization effect of process parameters, effectively improving the machining accuracy and performance of the blade disk. It is highly practical and suitable for widespread promotion and application.

[0028] Optionally, the dedicated software is NREC, specifically using NREC's MAX-PAC module to perform CNC simulation of the ball-end spiral bevel end mill, and to extract the cutting area and cutting edge length using NREC's MAX-PAC module. Optionally, the calculation software is CutPro.

[0029] In this embodiment, the calculation equation for the cutting force model in step S1 is:

[0030]

[0031] Wherein, the tangential, radial, and normal directions are set as the x, y, and z directions, respectively; the tangential direction is the tool feed direction; the radial direction is perpendicular to the rotation axis; and the normal direction is perpendicular to the tool feed direction. F x F y and F z Let x, y, and z be the cutting forces in the x, y, and z directions, respectively; l be the cutting edge length; b be the cutting width; θ be the angle between the axis of the ball-end spiral conical milling cutter and the surface to be machined on the blade disk; and k be the cutting force. xl k yl and k zl The cutting force coefficients, k, represent the cutting edge lengths in the x, y, and z directions, respectively. xs k ys and k zs These are the cutting force coefficients for the cutting areas in the x, y, and z directions, respectively.

[0032] Specifically, after conducting cutting tests using a ball-end spiral bevel end mill as the machining tool, multiple cutting forces can be obtained. By substituting these multiple cutting forces into the above calculation equation, multiple cutting force coefficients can be obtained. Then, by fitting these multiple cutting force coefficients, each cutting force coefficient in the above calculation equation can be determined.

[0033] In this embodiment, in step S2, the adjustment strategy is as follows: S21: Determine the cutting force component at the current machining deformation location using the cutting force model, and analyze the influence of the cutting force component on the cutting deformation. The cutting force component includes F... x F y and F z S22: Calculate the amount of cutting deformation at the current machining deformation location in the direction of the cutting force component, so as to construct the correlation function between the cutting parameters and the total cutting deformation. Then, perform sensitivity analysis on the cutting parameters through the correlation function to determine the cutting parameters to be adjusted first. At the same time, adjust the tilt angle of the worktable according to the magnitude of the cutting force component.

[0034] Specifically, the magnitude and direction of the cutting force are estimated using a cutting force model, and then the cutting force is divided into tangential force, normal force, and radial force. Based on the relationship between the cutting deformation in the direction of the cutting force component and the total cutting deformation, the relationship between cutting parameters and the cutting force component, and the relationship between the cutting force component and the cutting deformation in the direction of the cutting force component, a correlation function between the cutting parameters and the total cutting deformation can be constructed. This correlation function takes the cutting parameters as input, the intermediate quantities as the cutting force component and the cutting deformation in the direction of the cutting force component, and the output as the total cutting deformation. This correlation function transforms the complex relationship between cutting force, cutting deformation, and cutting parameters into a calculable and optimizable mathematical model. Sensitivity analysis of the cutting parameters is then performed using the correlation function to determine the cutting parameters to be adjusted preferentially. Since the tangential stiffness is the maximum directional stiffness of the blade, the radial stiffness is less than the tangential stiffness, and the normal stiffness is the smallest, the normal force has the greatest impact on cutting deformation. By adjusting the tilt angle of the worktable, the direction of the cutting force component can be optimized, reducing excessive cutting force in a certain direction. For example, when the normal force is too large, adjusting the tilt angle of the worktable can reduce the normal force.

[0035] It should be understood that, as a low-stiffness part, the blade disk is prone to cutting deformation during milling. However, the stiffness of the actual blade disk varies significantly in different directions. During milling, the cutting forces in each direction also differ, and the deformation caused by these forces in each direction has varying impacts on the total cutting deformation. Therefore, the cutting path is determined based on the principle of maximizing the stiffness of the cutting system to improve machining accuracy.

[0036] In this embodiment, the process of constructing the correlation function is as follows: S221, based on the cutting force model, determine the functional relationship between the cutting force and the cutting parameters; S222, based on the relationship between the cutting force and the cutting deformation, establish the influence model of the cutting component force on the cutting deformation; S223, combine the cutting force model and the influence model to obtain the correlation function of the cutting parameters on the total cutting deformation.

[0037] Specifically, by combining the cutting force model and the influence model, the correlation function between cutting parameters and total cutting deformation can be obtained through experimental data fitting, numerical simulation, or theoretical derivation. The core function of the correlation function is to quantify the influence of cutting parameters on deformation, and to adjust the cutting parameters through numerical optimization algorithms to achieve precise control of the machining process. By adjusting the cutting parameters, the relationship between cutting force and cutting deformation can be optimized, thereby improving the machining accuracy and efficiency of the blade disk and effectively enhancing its performance.

[0038] It should be understood that sensitivity analysis is to differentiate the correlation function. The cutting parameter with the highest sensitivity is the cutting parameter with the largest derivative, and the cutting parameter with the highest sensitivity is determined to be the cutting parameter to be adjusted first.

[0039] Cutting parameters include cutting speed, feed rate, and depth of cut. The depth of cut includes axial depth of cut and radial depth of cut. Since the cutting force model does not consider the cutting speed and the cutting speed has a small impact on the cutting force, the cutting speed is not involved in the adjustment of cutting parameters. Furthermore, the cutting speed is closely related to machining stability and is not suitable for adjustment. Therefore, the adjustment strategy is actually to adjust the feed rate and depth of cut, which determines the parameter range I of the feed rate and depth of cut.

[0040] In this embodiment, the correlation function is:

[0041]

[0042] Among them, D total Let p be the total cutting deformation, m be the cutting parameter vector, and K be the material parameter vector. iF K is the cutting force coefficient for the cutting edge length. iA k is the cutting force coefficient of the cutting area. i For directional stiffness.

[0043] Specifically, by using the aforementioned correlation function to correlate cutting force, cutting parameters, and total cutting deformation to a certain extent, the influence of different cutting parameters on cutting deformation can be evaluated. This allows for the optimization of cutting parameters, ensuring that cutting deformation remains within the allowable range and achieving optimal machining accuracy.

[0044] In this embodiment, the adjustment strategy also includes adjusting the tool feed direction and adjusting the tool angle. Specifically, for different stiffness directions, the tool feed direction is adjusted to match the direction of the cutting force with the blade stiffness, thereby reducing cutting deformation. For example, cutting is performed in the direction with greater tangential stiffness to reduce cutting deformation. By adjusting the tool angle, the excessive effect of the cutting force in a certain direction is reduced. For example, by tilting the tool angle, the normal component of the cutting force is minimized to avoid excessive cutting deformation in areas with lower normal stiffness.

[0045] In this embodiment, step S3, which involves performing modal testing on the blade disk blades to obtain modal parameters, specifically includes the following steps: dividing the blade disk blades into N regions with equal areas, marking the connection points of each region, and performing modal testing on each connection point to obtain the modal parameters of each connection point.

[0046] Specifically, the modal parameters of each connection point are obtained through the above steps to provide data support for the calculation of the stable processing region and parameter range.

[0047] Optionally, modal parameters include modal stiffness and damping.

[0048] In this embodiment, in step S3, the specific steps of sequentially calculating the parameter intervals of different processing parameters and spindle speeds by using calculation software include the following steps: calculating the stable processing area under the weak stiffness of the blade by using calculation software, then inputting the cutting force coefficient and the modal parameters of each connection point into the calculation software, and calculating to obtain parameter interval II of axial cutting depth and spindle speed in the blade curved surface coordinate system; according to the processing path, the inclination angle of the worktable and the mapping law of the blade curved surface coordinate system, establishing the correlation law between the axial cutting depth and radial cutting depth in the actual processing process and the axial cutting depth in the blade curved surface coordinate system, so as to obtain parameter interval III of cutting parameters and spindle speed in the actual processing process; calculating the stable processing area under the weak stiffness of the tool by using calculation software, then inputting the cutting force coefficient and the modal parameters of each connection point into the calculation software, and calculating to obtain parameter interval IV of axial cutting depth and spindle speed in the tool coordinate system.

[0049] Specifically, during the milling process of a blisk, both the tool and the blade are weak stiffness parts, and the stiffness of the blade is lower than that of the tool. Therefore, the stable processing area under the weak stiffness of the blade is calculated first, and then the stable processing area under the weak stiffness of the tool is calculated to obtain the stable processing process parameters, so as to realize low-deformation processing of the blisk.

[0050] It should be understood that the tool coordinate system is consistent with the actual processing coordinate system, so no conversion is required.

[0051] In this embodiment, the specific step of obtaining the effective processing parameter domain V through the intersection of multiple parameter intervals is: obtaining the processing parameter domain V through the intersection of parameter intervals II to IV, so as to select effective processing parameters from the processing parameter domain V, and determine the spindle speed within the processing parameter domain V in combination with parameter interval I.

[0052] Specifically, through the above steps, the maximum rotation speed allowed by the machine tool can be determined, so as to realize high-efficiency processing of the blisk.

[0053] Optionally, the processing system matched with the above processing method is a cutting force acquisition system. The cutting force acquisition system comprises a kislter dynamometer, a data acquisition system, a milling cutter, a test sample, a CNC composite machining center and a modal acquisition and analysis system. The kislter dynamometer and the data acquisition system are used for acquiring cutting force, the CNC composite machining center is used for carrying out turning and milling tests, the modal analysis system is used for carrying out modal tests to obtain modal parameters, the milling cutter is a ball-head spiral conical ball-head milling cutter, the test sample is a workpiece after rough processing of the blisk, and the processing allowance does not exceed 0.05 mm.

[0054] The aero-engine of this embodiment includes a blade disk, characterized in that the blade disk is manufactured using the aforementioned efficient and low-deformation machining method suitable for aero-engine blade disks. Specifically, by employing the aforementioned efficient and low-deformation machining method for aero-engine blade disks in the machining of the blade disk, the machining accuracy and performance of the blade disk are improved, thereby enhancing the performance of the aero-engine.

[0055] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

[0056] It should be noted that, in this document, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0057] This document uses specific examples to illustrate the principles and implementation methods of this application. The examples are merely for the purpose of helping to understand the method and core ideas of this application. The above descriptions are only preferred embodiments of this application. It should be noted that due to the limitations of written expression, and the existence of an infinite number of specific structures, those skilled in the art can make various improvements, modifications, or variations without departing from the principles of this application, and can also combine the above technical features in an appropriate manner. These improvements, modifications, variations, or combinations, or the direct application of the concept and technical solution of this application to other situations without modification, should all be considered as protected by this application.

Claims

1. A high-efficiency, low-deformation machining method suitable for aircraft blade disks, characterized in that, Includes the following steps: S1: Construct a cutting force model based on a ball-end spiral conical end mill and conduct cutting tests using the ball-end spiral conical end mill as the machining tool to determine the cutting force coefficient in the cutting force model; S2: By using specialized software to perform CNC simulation of the ball-end spiral conical milling cutter, the machining path is determined based on the principle of maximizing the stiffness of the cutting system. A blade surface coordinate system is constructed based on the blade disk surface. Then, based on the machining path, the cutting area and cutting edge length are extracted using specialized software to calculate the real-time cutting force in the machining path. A finite element model of the blade disk is then constructed to conduct transient mechanical analysis in the blade surface coordinate system. Based on the machining path and real-time cutting force, the cutting component force that applies the load to the blades in the blade disk is determined. The stiffness of the blades in the blade disk in the direction of the cutting component force is calculated to determine whether the cutting deformation is within the set range. When the cutting deformation exceeds the set range, the cutting parameters at the current machining deformation point and the tilt angle of the worktable are adjusted according to the adjustment strategy to determine the parameter range I of feed rate and depth of cut. S3: Conduct modal testing on the blades of the blade disk to obtain modal parameters, then use calculation software to calculate the parameter ranges of different machining parameters and spindle speeds in sequence, and then obtain the effective machining parameters through multiple parameter ranges; In step S1, the calculation equation for the cutting force model is: ； ； ； In this context, the tangential, radial, and normal directions are defined as the x, y, and z directions, respectively. The tangential direction is the tool feed direction, the radial direction is perpendicular to the rotation axis, and the normal direction is perpendicular to the tool feed direction. , and These represent the cutting forces in the x, y, and z directions, respectively. l b is the cutting edge length, and b is the cutting width. The angle between the axis of the ball-end spiral conical end mill and the surface to be machined on the blade disk. , and These are the cutting force coefficients for the cutting edge lengths in the x, y, and z directions, respectively. , and These are the cutting force coefficients for the cutting areas in the x, y, and z directions, respectively.

2. The efficient and low-deformation machining method for aircraft blade disks according to claim 1, characterized in that, In step S2, the adjustment strategy is as follows: S21: Determine the cutting force component at the current machining deformation point using the cutting force model, and analyze the influence of the cutting force component on the cutting deformation. The cutting force component includes... , and ; S22: Calculate the amount of cutting deformation at the current machining deformation location in the direction of the cutting force component, so as to construct the correlation function between the cutting parameters and the total cutting deformation. Then, perform sensitivity analysis on the cutting parameters through the correlation function to determine the cutting parameters to be adjusted first. At the same time, adjust the tilt angle of the worktable according to the magnitude of the cutting force component.

3. The efficient and low-deformation machining method for aircraft blade disks according to claim 2, characterized in that, The process of constructing the association function is as follows: S221, based on the cutting force model, determines the functional relationship between cutting force and cutting parameters; S222, Based on the relationship between cutting force and cutting deformation, a model of the influence of cutting force component on cutting deformation is established; S223 combines the cutting force model with the influence model to obtain the correlation function of cutting parameters with total cutting deformation.

4. The efficient and low-deformation machining method for aircraft blade disks according to claim 1, characterized in that, The correlation function is: ； Among them, D total For total cutting deformation, p Let m be the cutting parameter vector, and K be the material parameter vector. iF K is the cutting force coefficient for the cutting edge length. iA k is the cutting force coefficient of the cutting area. i For directional stiffness.

5. The efficient and low-deformation machining method for aircraft blade disks according to claim 2, characterized in that, The adjustment strategy also includes adjusting the tool feed direction and adjusting the tool angle.

6. The efficient and low-deformation machining method for aircraft blade disks according to any one of claims 1-5, characterized in that, Step S3, which involves conducting modal testing on the blades of the blade disk to obtain modal parameters, specifically includes the following steps: The blade disk blades are divided into N regions with equal areas, the connection points of each region are marked, and modal tests are carried out on each connection point to obtain the modal parameters of each connection point.

7. The efficient and low-deformation machining method for aircraft blade disks according to claim 6, characterized in that, In step S3, the calculation software is used to sequentially calculate the parameter ranges for different machining parameters and spindle speeds, specifically including the following steps: The stable machining region under weak stiffness of the blade is calculated using calculation software. Then, the cutting force coefficient and modal parameters of each connection point are input into the calculation software to calculate the parameter range II of axial cutting depth and spindle speed in the blade surface coordinate system. Based on the mapping law between the machining path, the tilt angle of the worktable and the blade surface coordinate system, the correlation law between the axial cutting depth and radial cutting depth and the axial cutting depth in the blade surface coordinate system during the actual machining process is established, so as to obtain the parameter range III of the cutting parameters and spindle speed during the actual machining process. The stable machining region under weak tool stiffness is calculated using calculation software. Then, the cutting force coefficient and modal parameters of each connection point are input into the calculation software to calculate the parameter range IV of axial cutting depth and spindle speed in the tool coordinate system.

8. The efficient and low-deformation machining method for aircraft blade disks according to claim 7, characterized in that, The specific steps to obtain the effective processing parameter domain V by the intersection of multiple parameter intervals are as follows: The machining parameter domain V is obtained by the intersection of parameter intervals II-IV. Effective machining parameters are selected from the machining parameter domain V, and combined with parameter interval I, the spindle speed within the machining parameter domain V is determined.

9. An aircraft engine, comprising a blade disk, characterized in that, The blade disk is manufactured using the efficient and low-deformation machining method for aerospace blade disks as described in any one of claims 1-8.

Images