Non-coaxial double-pivot turbulent flow blade and machining method

Abstract

The invention belongs to the field of machining, and discloses a non-coaxial double-pivot turbulent flow blade and a machining method.The method comprises the steps that a square reference block is milled in the middle of a square blank, the plane of the square reference block serves as a unified positioning reference penetrating through the whole machining process, and milling machining, reference block cutting and contact area polishing of a blade body and two pivots are sequentially completed; and finally, the non-coaxial double-pivot turbulent flow blade is obtained. According to the standard unification principle, accumulative errors caused by multiple times of standard conversion in a traditional technology are thoroughly eliminated, and the machining precision and the product percent of pass of the non-coaxial double-pivot turbulent flow blade are remarkably improved. Meanwhile, a plurality of complex procedures and special tools such as center hole drilling, tin-bismuth alloy packaging and bag removing in the traditional process are omitted, the tool structure is simplified, the production period is shortened, the production cost is reduced, reliable technical support is provided for high-precision and high-efficiency batch production of key pneumatic components in the fields of gas turbines and aero-engines, and the production efficiency is improved. Wide application prospects and popularization values are realized.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of mechanical processing, and relates to a non-coaxial double-pivot vane and a processing method. BACKGROUND

[0002] A certain type of gas turbine vane is a typical non-coaxial double-pivot vane, which includes a left vane shaft, a vane body and a right vane shaft, and is processed by using a whole square blank. The core feature of the vane is that the pivot axes at the left and right ends are not on the same straight line, and the vane body has a complex aerodynamic profile. This special structure brings great challenges to processing and manufacturing.

[0003] At present, the processing of this type of non-coaxial double-pivot vane mainly adopts the following process scheme: first, process two coaxial tailstock holes at the ends of the square blank as initial reference, then mill the vane profile and the inner surface of the mounting plate based on the initial reference, then use a cylindrical mold to cooperate with low-melting-point tin-bismuth alloy to pour and package the processed vane body to form a temporary process reference, and then process the two end pivots based on the package body as reference, and finally remove the tin-bismuth alloy by heating and melting to complete the processing of the vane.

[0004] However, this process method has the following significant defects: 1. Complex process flow, low processing efficiency. The entire processing process needs to go through multiple processes, especially the tin-bismuth alloy packaging and unpacking process takes a long time, and special packaging molds and auxiliary materials are needed, resulting in a large number of tooling, high processing cost, and long production cycle. 2. The processing precision is difficult to guarantee, and the product qualified rate is low. In the processing process, multiple reference conversions are needed, from the initial tailstock hole reference to the vane profile reference, and then to the temporary reference formed by the tin-bismuth alloy packaging, each reference conversion will introduce new positioning error and clamping error, and will produce obvious error accumulation effect. For the non-coaxial double-pivot structure with extremely high precision requirements, this error accumulation will directly lead to the relative position relationship of the left and right pivots being out of tolerance, affecting the aerodynamic performance and assembly precision of the vane, and the product qualified rate is low. SUMMARY

[0005] The purpose of the present application is to overcome the above-mentioned defects of the prior art, and to provide a non-coaxial double-pivot vane and a processing method.

[0006] To achieve the above-mentioned purpose, the present application adopts the following technical solutions: In the first aspect, the application provides a non-coaxial double-pivot spoiler blade processing method, comprising: milling a square reference block on the middle region of a square blank; taking the plane of the square reference block as a positioning reference to mill the blade body and two pivots of the non-coaxial double-pivot spoiler blade on the square blank to obtain a primary processing blade; taking the plane of the square reference block as a positioning reference, and based on the requirement of reserving a preset first processing allowance in the contact region between the blade body and the square reference block, cutting the square reference block to obtain a rough processing blade; polishing the contact region on the rough processing blade to obtain a non-coaxial double-pivot spoiler blade.

[0007] Optionally, the milling of the blade body and the two pivots of the non-coaxial double-pivot spoiler blade on the square blank to obtain a primary processing blade comprises: taking the plane of the square reference block as a positioning reference, and based on the requirement of reserving a preset second processing allowance, rough milling the blade body and the two pivots of the non-coaxial double-pivot spoiler blade on the square blank to obtain a rough milling blank; taking the plane of the square reference block as a positioning reference, and based on the requirement of reserving a preset third processing allowance in the blade body profile, fine milling the blade body and the two pivots of the non-coaxial double-pivot spoiler blade on the rough milling blank to obtain a fine milling blank; polishing the blade body of the non-coaxial double-pivot spoiler blade on the fine milling blank to obtain a primary processing blade.

[0008] Optionally, the rough milling of the blade body and the two pivots of the non-coaxial double-pivot spoiler blade on the square blank comprises: taking the plane of the square reference block as a positioning reference, clamping the square blank on a four-coordinate machining center turntable clamp, and rough milling the blade body and the two pivots of the non-coaxial double-pivot spoiler blade.

[0009] Optionally, the fine milling of the blade body and the two pivots of the non-coaxial double-pivot spoiler blade on the rough milling blank comprises: taking the plane of the square reference block as a positioning reference, clamping the rough milling blank on a five-coordinate machining center turntable clamp, and fine milling the blade body and the two pivots of the non-coaxial double-pivot spoiler blade.

[0010] Optionally, before the fine milling of the blade body and the two pivots of the non-coaxial double-pivot spoiler blade on the rough milling blank, the method further comprises: vacuum heat treating the rough milling blank; wherein the parameters of the vacuum heat treatment are: temperature 645℃±10℃, time 4h±15min.

[0011] Optionally, the second processing allowance is 1-2mm.

[0012] Optionally, the third processing allowance is 0.01-0.05mm.

[0013] Optionally, the first processing allowance is 1-2mm.

[0014] Optionally, when the square reference block is cut, a wire cutting method is used to cut the square reference block.

[0015] In the second aspect, the application provides a non-coaxial double-pivot spoiler blade, which is processed by the non-coaxial double-pivot spoiler blade processing method.

[0016] Compared with the prior art, the application has the following beneficial effects: The non-coaxial double-pivot spoiler blade processing method of the application avoids the influence of multiple conversion of processing positioning reference by innovatively milling a square reference block in the middle region of the square blank and taking the plane of the square reference block as a unified positioning reference throughout the entire processing flow. Specifically, the milling of the blade body and the two pivots is first completed by taking the plane of the square reference block as the positioning reference, then the cutting of the square reference block is still performed by taking the plane of the square reference block as the positioning reference, and a processing allowance is reserved in the contact region, and finally the finished non-coaxial double-pivot spoiler blade is obtained by polishing. This process flow eliminates the cumulative error caused by multiple positioning reference conversion (such as conversion from the center hole reference to the tin-lead alloy sealing package reference) in the traditional process by the reference unification principle, so that the processing precision of the non-coaxial double-pivot spoiler blade is significantly improved, and the product qualification rate is greatly improved. At the same time, the method eliminates multiple complex processes such as tapping center holes, tin-lead alloy sealing and unpacking in the traditional process and the corresponding special tooling, which not only simplifies the tooling structure and reduces the number of tooling, but also significantly shortens the production cycle and reduces the production cost. The method provides reliable technical support for low-cost, high-precision and high-efficiency batch production of key aerodynamic components in the field of gas turbines and aero-engines, and has wide application prospect and promotion value.

[0017] The non-coaxial double-pivot spoiler blade of the application avoids the cumulative error caused by multiple switching of positioning reference during processing, so that the spatial positional relationship between the most critical non-coaxial double-pivot spoiler blades reaches high accuracy and consistency, thereby ensuring that the non-coaxial double-pivot spoiler blade can be precisely assembled and smoothly actuated in the gas turbine or aero-engine, thereby ensuring the performance and stability of the gas turbine or aero-engine under extreme working conditions, and effectively improving the service life. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 The figure is a flow chart of the non-coaxial double-pivot spoiler blade processing method of the embodiment of the application.

[0019] Figure 2 The figure is a schematic diagram of the non-coaxial double-pivot spoiler blade design and the square reference block of the embodiment of the application.

[0020] Figure 3 The figure is a schematic diagram of the rough processing blade of the embodiment of the application.

[0021] Wherein: 1-square reference block; 2-square blank; 3-vane left axis; 4-vane right axis; 5-vane body; 6-contact area of vane body and square reference block. DETAILED DESCRIPTION

[0022] Hereinafter, only certain exemplary embodiments are simply described. As those skilled in the art can recognize, the described embodiments can be modified in various different ways without departing from the spirit or scope of the present application. Therefore, the drawings and description are considered to be exemplary in nature rather than limiting.

[0023] In the description of the present application, it is to be understood that the orientations or positional relationships indicated by the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like are based on the orientations or positional relationships shown in the drawings, and are only for the purpose of facilitating the description of the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0024] In addition, the terms "first", "second", "third", etc. are only for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features referred to. Therefore, the features defined with "first", "second", etc. can explicitly or implicitly include one or more of the features. In the description of the present application, the meaning of "a plurality of" is two or more, unless otherwise explicitly specified and limited.

[0025] In the present application, unless otherwise explicitly specified and limited, the terms "mounting", "connection", "connecting", "fixing" and the like should be broadly understood, for example, can be fixed connection, can also be detachable connection, or integral; can be mechanical connection, can also be electrical connection, or communication; can be directly connected, or indirectly connected through an intermediate medium; can be the internal communication of two elements or the interaction relationship between two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0026] In the present application, unless otherwise explicitly specified and limited, the first feature is "on" or "under" the second feature can include that the first and second features are in direct contact, or can include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, the first feature is "on", "above" and "over" the second feature includes that the first feature is directly above and obliquely above the second feature, or only indicates that the first feature is higher in horizontal height than the second feature. The first feature is "under", "below" and "underneath" the second feature includes that the first feature is directly above and obliquely above the second feature, or only indicates that the first feature is lower in horizontal height than the second feature.

[0027] It should be understood that the terms "comprises" and "comprising" as used herein, indicate the presence of the described features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0028] It should also be understood that the terms used in the present application specification are only for the purpose of describing particular embodiments and are not intended to limit the present application. As used in the present application specification and the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms unless the context clearly indicates otherwise.

[0029] It should be further understood that the term "and / or" as used in the present application specification and the appended claims, means any combination of one or more of the associated listed items and all possible combinations thereof.

[0030] Various structural diagrams according to the disclosed embodiments of the present application are shown in the accompanying drawings. These drawings are not drawn to scale, in which certain details are exaggerated for the purpose of clarity and certain details can be omitted. The shapes of various regions, layers and their relative sizes and positional relationships shown in the drawings are only exemplary, and in actuality can be deviated due to manufacturing tolerances or technical limitations, and regions / layers with different shapes, sizes and relative positions can be additionally designed by those skilled in the art according to actual needs.

[0031] The embodiments of the present application are described in detail below with reference to the accompanying drawings.

[0032] Referring to Figure 1 In an embodiment of the present application, a non-coaxial double-pivot spoiler blade processing method is provided, which can effectively solve the problems of existing non-coaxial double-pivot spoiler blade processing methods, such as complex processing, high cost, long cycle, large processing error accumulation and low processing qualification rate.

[0033] Specifically, the non-coaxial double-pivot blade machining method comprises the following steps: Step 1: milling a square reference block 1 on the middle region of the square blank 2.

[0034] Step 2: taking the plane of the square reference block 1 as a positioning reference, milling the blade body 5 and the two pivots of the non-coaxial double-pivot blade on the square blank 2 to obtain a rough machining blade.

[0035] Step 3: taking the plane of the square reference block 1 as a positioning reference, cutting the square reference block 1 based on the cutting requirement of reserving a preset first machining allowance in the contact region 6 between the blade body and the square reference block to obtain a rough machining blade.

[0036] Step 4: polishing the contact region on the rough machining blade to obtain the non-coaxial double-pivot blade.

[0037] The non-coaxial double-pivot blade machining method avoids the influence of multiple conversion of the machining positioning reference while ensuring the relative position accuracy of high machining positioning by innovatively milling the square reference block 1 in the middle region of the square blank 2 and taking the plane of the square reference block 1 as a unified positioning reference throughout the entire machining process. Specifically, the milling of the blade body 5 and the two pivots is first completed by taking the plane of the square reference block 1 as a positioning reference, then the cutting of the square reference block 1 is performed by still taking the plane of the square reference block 1 as a positioning reference, and a machining allowance is reserved in the contact region, and finally the finished non-coaxial double-pivot blade is obtained through polishing. This process eliminates the cumulative error caused by multiple conversion of the positioning reference (such as conversion from the center hole reference to the tin-lead alloy sealing package reference) in the traditional process by the principle of reference unification, significantly improves the machining accuracy of the non-coaxial double-pivot blade, and greatly improves the product qualification rate. At the same time, the method eliminates multiple complex processes such as tapping center holes, tin-lead alloy sealing and unpacking in the traditional process and the corresponding special tooling, not only simplifies the tooling structure and reduces the number of toolings, but also significantly shortens the production cycle and reduces the production cost, providing reliable technical support for low-cost, high-precision and high-efficiency batch production of key aerodynamic components in the field of gas turbines and aeroengines, and having broad application prospects and promotional value.

[0038] Explanatorily, referring to Figure 2 , the two pivots are the blade left axis 3 and the blade right axis 4 of the non-coaxial double-pivot blade, and the axes of the blade left axis 3 and the blade right axis 4 are not on the same straight line.

[0039] Explanatorily, referring to Figure 2When milling the reference block on the middle region of the square blank 2, the square reference block 1 is selected, because the square reference block 1 can follow the six-point positioning principle in machining, that is, it can stably and accurately limit all six spatial degrees of freedom of the workpiece in one clamping, thereby establishing a unique and reliable positioning reference throughout the entire machining process. Compared with the traditional indirect and variable reference such as the tailstock hole or the bismuth alloy package, the square reference block 1 machined directly from the part body blank not only eliminates the cumulative error caused by multiple reference conversions, ensures the high relative position accuracy between the non-coaxial pivots, and does not need to design and manufacture complex special tooling (such as a package mold), thereby simplifying the process, reducing the cost, and shortening the production cycle at the root.

[0040] In a possible implementation, the milling of the blade body 5 and the two pivots of the non-coaxial double-pivot spoiler blade on the square blank 2 based on the plane of the square reference block 1 as the positioning reference includes: rough milling the blade body 5 and the two pivots of the non-coaxial double-pivot spoiler blade on the square blank 2 based on the requirement of reserving a preset second machining allowance, to obtain a rough-milled blank; fine milling the blade body 5 and the two pivots of the non-coaxial double-pivot spoiler blade on the rough-milled blank based on the requirement of reserving a preset third machining allowance for the blade body profile, to obtain a fine-milled blank; polishing the blade body 5 of the non-coaxial double-pivot spoiler blade on the fine-milled blank, to obtain a primary processed blade.

[0041] Explanatorily, by setting and gradually reducing the machining allowance in stages, most of the material can be efficiently removed and internal stress can be released in the rough machining stage, and the profile fine milling can be completed in a stable state with smaller cutting force in the fine machining stage, which not only effectively controls the deformation of the workpiece, but also effectively improves the surface quality, thereby realizing the best balance between machining efficiency and tool life on the premise of ensuring machining quality and reliability.

[0042] In a possible implementation, the rough milling of the blade body 5 and the two pivots of the non-coaxial double-pivot spoiler blade on the square blank 2 includes: clamping the square blank 2 on a four-coordinate machining center rotary table clamp based on the plane of the square reference block 1, and rough milling the blade body 5 and the two pivots of the non-coaxial double-pivot spoiler blade.

[0043] In a possible implementation, the fine milling of the blade body 5 and the two pivots of the non-coaxial double-pivot spoiler blade on the rough-milled blank includes: clamping the rough-milled blank on a five-coordinate machining center rotary table clamp based on the plane of the square reference block 1, and fine milling the blade body 5 and the two pivots of the non-coaxial double-pivot spoiler blade.

[0044] Optionally, the second machining allowance is 1~2mm, and the third machining allowance is 0.01~0.05mm.

[0045] Explaining the implications, using a four-axis machining center for roughing not only meets the basic rotation angle requirements for shaping the blade body and the two pivots, but also fully leverages its advantages of low equipment cost and high structural rigidity, achieving efficient and stable removal of large amounts of material. Switching to a five-axis machining center during the finishing stage, with its additional tilting head or rotary table functions, allows for optimal tool entry angles and better linear speed control for complex, continuous spatial surfaces, effectively ensuring the final accuracy and surface quality of the blade body. This combined approach ensures the processing capability of critical processes while optimizing the workload of expensive five-axis equipment, achieving a highly efficient balance between machining accuracy and production costs.

[0046] In one possible implementation, before finishing milling the blade body 5 and the two pivots of the non-coaxial double-pivot spoiler blade on the rough milling blank, the process further includes: performing vacuum heat treatment on the rough milling blank; wherein the parameters of the vacuum heat treatment are: temperature 645℃±10℃, time 4h±15min.

[0047] Explanatoryly, introducing a vacuum heat treatment process before finishing milling on the rough milled blank can effectively eliminate the macroscopic residual stress and microscopic lattice distortion generated inside the workpiece due to the large allowance cutting during the rough milling stage. This significantly reduces the risk of deformation caused by stress release during subsequent finishing and use, thereby ensuring the stability of the workpiece dimensions during the finishing stage. This provides a basis for obtaining high-precision blade profiles and the positions of the two pivots. At the same time, the vacuum environment can also effectively prevent material surface oxidation and ensure the surface quality of the workpiece.

[0048] In one possible implementation, the first machining allowance is 1~2mm.

[0049] In one possible implementation, the non-coaxial dual-pivot spoiler blade processing method of the present invention uses wire cutting to cut the square reference block 1 when cutting the square reference block 1.

[0050] Explained, wire EDM, as a non-contact precision machining method, does not involve mechanical cutting forces during the machining process. Therefore, it can completely avoid blade deformation or precision damage caused by clamping or cutting forces, and is especially suitable for the subsequent processing of precision blade bodies that have already been machined.

[0051] By using wire cutting, the square reference block 1 can be precisely separated along a preset path, which can effectively control the processing quality of the contact area and provide a uniform allowance for subsequent polishing processes. At the same time, it can also ensure the dimensional consistency of the blades after cutting, further improving the reliability of processing and the yield of finished products.

[0052] In another embodiment of the present invention, a non-coaxial dual-pivot spoiler blade is provided, which is obtained by the above-described non-coaxial dual-pivot spoiler blade processing method.

[0053] The non-coaxial dual-pivot spoiler blade of this invention avoids the cumulative error caused by multiple switching of positioning references during the manufacturing process. This allows the spatial positional relationship between the two non-coaxial pivots, which is the most critical aspect of the non-coaxial dual-pivot spoiler blade, to achieve high precision and consistency. As a result, the non-coaxial dual-pivot spoiler blade can be precisely assembled and smoothly operated in gas turbines or aero engines, thereby ensuring the performance and stability of gas turbines or aero engines under extreme operating conditions and effectively extending their service life.

[0054] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the scope of the invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0055] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can be appropriately combined to form other embodiments that can be understood by those skilled in the art. The above content is only for illustrating the technical concept of the present invention and should not be construed as limiting the scope of protection of the present invention. Any modifications made based on the technical concept proposed in this invention shall fall within the scope of protection of the claims of this invention.

Claims

1. A method for manufacturing non-coaxial double-pivot spoiler blades, characterized in that, include: A square reference block (1) is milled in the middle area of ​​the square blank (2); Using the plane of the square reference block (1) as the positioning reference, the blade body (5) and two pivots of the non-coaxial double pivot turbulence blade are milled on the square blank (2) to obtain the initial machined blade; Using the plane of the square reference block (1) as the positioning reference, and based on the cutting requirement of reserving a preset first machining allowance in the contact area (6) between the blade and the square reference block, the square reference block (1) is cut to obtain the rough-machined blade. Polishing the contact area on the rough-machined blades yields non-coaxial double-pivot spoiler blades.

2. The method for processing non-coaxial double-pivot spoiler blades according to claim 1, characterized in that, Using the plane of the square reference block (1) as the positioning reference, the blade body (5) and two pivots of the non-coaxial double-pivot spoiler blade are milled on the square blank (2) to obtain the initial machined blade, which includes: Using the plane of the square reference block (1) as the positioning reference, and based on the requirement of reserving a second machining allowance, the blade body (5) and two pivots of the non-coaxial double pivot turbulence blade are rough milled on the square blank (2) to obtain the rough milled blank. Using the plane of the square reference block (1) as the positioning reference, and based on the requirement of reserving a third machining allowance on the blade body (5) profile, the blade body (5) and two pivots of the non-coaxial double pivot turbulence blade are finely milled on the rough milling blank to obtain the fine milling blank; Polish and finish mill the blade body (5) of the non-coaxial double pivot turbulence blade on the blank to obtain the initial machined blade.

3. The method for processing non-coaxial double-pivot spoiler blades according to claim 2, characterized in that, The rough milling of the blade body (5) and two pivots of the non-coaxial double-pivot spoiler blade on the square blank (2) includes: Using the plane of the square reference block (1) as the positioning reference, the square blank (2) is clamped on the turntable fixture of the four-axis machining center, and the blade body (5) and two pivots of the non-coaxial double-pivot turbulence blade are rough milled.

4. The method for processing non-coaxial double-pivot spoiler blades according to claim 2, characterized in that, The process of finish milling the blade body (5) and two pivots of the non-coaxial double-pivot spoiler blade on the rough milling blank includes: Using the plane of the square reference block (1) as the positioning reference, the rough milling blank is clamped on the turntable fixture of the five-axis machining center, and the blade body (5) and two pivots of the non-coaxial double pivot turbulence blade are finished milled.

5. The method for processing non-coaxial double-pivot spoiler blades according to claim 2, characterized in that, Before finishing milling the blade body (5) and the two pivots of the non-coaxial double-pivot spoiler blade on the rough milling blank, the process also includes: The rough milled blank is subjected to vacuum heat treatment; The parameters for vacuum heat treatment are: temperature 645℃±10℃, time 4h±15min.

6. The method for processing non-coaxial double-pivot spoiler blades according to claim 2, characterized in that, The second machining allowance is 1~2mm.

7. The method for processing non-coaxial double-pivot spoiler blades according to claim 2, characterized in that, The third machining allowance is 0.01~0.05mm.

8. The method for processing non-coaxial double-pivot spoiler blades according to claim 1, characterized in that, The first machining allowance is 1~2mm.

9. The method for processing non-coaxial double-pivot spoiler blades according to claim 1, characterized in that, When cutting the square reference block (1), the square reference block (1) is cut by wire cutting.

10. A non-coaxial double-pivot spoiler blade, characterized in that, The non-coaxial double-pivot spoiler blade is manufactured using the non-coaxial double-pivot spoiler blade manufacturing method according to any one of claims 1 to 9.

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