A method for processing a high-temperature alloy blisk
By combining layered spiral milling of the blade profile with an adjustable auxiliary support machining fixture, the problems of excessive blade profile deviation and large tool wear in the machining of high-temperature alloy integral bladed disks were solved, achieving high-efficiency, low-cost, and high-quality machining.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- AECC AERO SCI & TECH CO LTD
- Filing Date
- 2026-05-18
- Publication Date
- 2026-06-30
AI Technical Summary
When machining high-temperature alloys, integral bladed disks suffer from problems such as excessive blade profile deviation, excessive tool wear, and easy deformation of the spokes, resulting in high processing costs and substandard product quality.
The blade section is machined using a layered spiral milling method, combined with an adjustable auxiliary support machining fixture. Rough turning, rough milling, finish milling and finish turning are performed in steps to control the machining allowance of the blade and the disk. Larger tools and flexible support structures are used to reduce deformation.
It improves tool life, reduces machining costs, ensures the blade profile matches the theoretical blade profile, reduces part deformation, and improves product quality.
Smart Images
Figure CN122299339A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of machining integral bladed disks, and more particularly to a method for machining a high-temperature alloy integral bladed disk. Background Technology
[0002] Integral bladed disks (IBDs) are a new type of structural component designed to meet the requirements of high-performance aero engines. They integrate the engine rotor blades and the disk into a single unit, eliminating the need for tenons, mortises, and locking devices found in traditional connections. This reduces structural weight and the number of parts, avoids airflow losses from tenons, improves aerodynamic efficiency, and significantly simplifies the engine structure. IBDs are primarily manufactured using CNC machining, electrolytic machining, electrochemical machining, and linear friction welding. Due to its advantages such as rapid response, simple tooling, and high process maturity, CNC machining has become the preferred choice for manufacturers of IBDs during the new product development stage.
[0003] The blades of integral bladed disks are thin-walled structures with poor machining rigidity. Traditional blade milling methods easily cause blade chatter and deformation during machining. Currently, the industry mainly uses a "one-to-two" blade milling strategy. This strategy retains the rough material between the blades, and during blade finishing, the removal of this rough material and the finishing process are performed simultaneously. This method can effectively enhance the machining rigidity of the blades. However, when machining high-temperature alloy integral bladed disks, using the traditional integral bladed disk machining strategy will encounter the following problems:
[0004] (1) The blade profile is out of tolerance. Compared with titanium alloy, high temperature alloy is much more difficult to cut. Its strength and hardness are greater than those of titanium alloy. Commonly used tools and milling strategies will be difficult to use when machining integral bladed disks of high temperature alloy. Less material is removed during milling, and the tool is subjected to greater force deviation, which is commonly known as tool deflection. Ultimately, this results in excessive residual material in the blade profile, which does not meet the requirements of the design drawings.
[0005] (2) High tool wear and high processing costs. Due to the difficult-to-machine characteristics of high-temperature alloys, commonly used tools are worn out faster and more frequently, resulting in a sharp increase in processing costs.
[0006] (3) The spokes are prone to deformation during turning. When turning the spoke area with a traditional turning fixture, an upward warping can be observed in the spoke area far from the positioning surface after machining, resulting in dimensional deviations. Summary of the Invention
[0007] In view of this, this application provides a processing method for a high-temperature alloy integral bladed disk, which solves the problems in the prior art and improves the product quality of the high-temperature alloy integral bladed disk.
[0008] The processing method for a high-temperature alloy integral bladed disk provided in this application adopts the following technical solution: A method for processing a high-temperature alloy integral bladed disk includes: Step 1: Roughly turn the outline of the integral bladed disk blank to obtain the rough-turned part; Step 2: Machining positioning holes on the rough-machined part to determine the blade angle direction in subsequent steps; Step 3: Rough milling of the rough-machined parts. During rough milling, remove all the burrs between the blades and leave machining allowance in the blade area. Step 4: Perform corrosion resistance inspection and vacuum stress relief heat treatment on the rough-milled parts, and repair the reference datum of the rough-milled parts; Step 5: The rough milled part from Step 4 is milled in the following order: plunge milling of the leading edge, plunge milling of the trailing edge, milling of the blade tip, layered spiral milling of the blade shape, finish milling of the flow channel, and root cleaning. The blade shape of the finish milled part is consistent with the dimensions of the theoretical blade shape of the part. Step 6: Perform precision turning on the disc body part of the precision-milled part.
[0009] Optionally, in step 1, the rough-machined part has a 1.5mm margin compared to the theoretical disc size, the rough-machined part has a 1mm margin compared to the theoretical blade size, and the rough-machined part has a 0.5mm margin compared to the theoretical blade tip.
[0010] Optionally, in step 3, the machining allowance for the blade-shaped part is 0.5mm.
[0011] Optionally, in step 5, the method for layered helical milling of the blade-shaped portion is as follows: Create a multi-layered helical milling toolpath from the blade tip to the blade root. The innermost helical milling toolpath mills the blade profile to conform to the theoretical blade profile design of the part. For two adjacent helical milling toolpaths, the outer helical milling toolpath leads the inner helical milling toolpath by a certain number of revolutions. For any two adjacent helical milling toolpaths, the outer helical milling toolpath leads the inner helical milling toolpath by the same number of revolutions. The cutting amount of the innermost helical milling toolpath is 0.07-0.1 mm, and the cutting amount of all other helical milling toolpaths is 0.2-0.3 mm.
[0012] Optionally, during the layered helical milling of the blade section, a three-layer helical milling toolpath is created from the blade tip to the blade root, with the outermost helical milling toolpath having a cutting amount of 0.2 mm, the middle helical milling toolpath having a cutting amount of 0.2 mm, and the innermost helical milling toolpath having a cutting amount of 0.1 mm.
[0013] Optionally, the outer spiral milling toolpath leads the inner spiral milling toolpath by 4 revolutions.
[0014] Optionally, in step 5, a D8R3 tapered ball end mill is used to perform layered helical milling of the leaf-shaped part. The spindle speed of the innermost helical milling toolpath is 4509 rpm, and the feed rate is set to 541 mm / min. The spindle speed of the other helical milling toolpaths is 1646 rpm, and the feed rate is set to 40% of the feed rate of the innermost helical milling toolpath.
[0015] Optionally, step 6, the step of precision turning the disc body portion of the precision-milled part, includes: Semi-finish machining is performed on both ends of the disc until the remaining material of the disc is 0.5mm; The two ends of the semi-finished disc are then finished to remove the remaining 0.5mm allowance.
[0016] Optionally, in step 6, after the precision-milled part is clamped by the vertical lathe machining fixture, the disc part of the precision-milled part is precision-machined. The vertical lathe fixture includes a positioning structure and an adjustable auxiliary support structure. The positioning structure is used to cooperate with the positioning hole on the precision-milled part. The support end of the adjustable auxiliary support structure is used to face the end face near the center on the side of the disc part that is opposite to the machining surface during the precision machining of the disc part.
[0017] In summary, this application includes the following beneficial technical effects: Since this application abandons the roughing and finishing milling strategy, the tool used for finishing milling no longer needs to remove the large amount of material between the blades. It only needs to mill off the material of less than 0.5mm on the blade surface. Larger tools with stronger milling capabilities can be selected to remove the large amount of material between the blades, thereby improving the tool life and reducing costs.
[0018] Due to the high rigidity of the high-temperature alloy, this application leaves a smaller allowance for the final milling of the blade profile. This results in a shorter machining time for each blade during the milling process, ensuring less tool wear and reducing the risk of tool shaft misalignment due to excessive cutting force. Ultimately, this ensures a high degree of agreement between the machined blade profile and the theoretical blade profile cross-section, significantly improving product quality.
[0019] This application employs an adjustable auxiliary support machining fixture design, allowing the part to deform and spring back freely during turning, preventing spoke bending caused by the cutting force acting between the positioning datum and the auxiliary support. Simultaneously, a smaller depth of cut and less material removal reduce the cutting force during part machining and also minimize part deformation. Attached Figure Description
[0020] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0021] Figure 1 This is a schematic diagram of the overall structure of the high-temperature alloy integral bladed disk in the embodiments of this application; Figure 2 This is a schematic diagram of the cross-sectional structure of the high-temperature alloy integral bladed disk in the embodiments of this application; Figure 3 This is a schematic diagram of the vertical lathe machining fixture in the embodiments of this application.
[0022] Explanation of reference numerals in the attached drawings: 1. Disc body; 2. Blade shape; 3. Blade tip; 4. Positioning hole; 5. Annular plane; 6. Positioning structure; 7. Adjustable auxiliary support structure. Detailed Implementation
[0023] The embodiments of this application will now be described in detail with reference to the accompanying drawings.
[0024] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. Obviously, the described embodiments are only one part of the embodiments of this application, and not all of them. This application can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be noted that, in the absence of conflict, the following embodiments and features in the embodiments can be combined with each other. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0025] It should be noted that various aspects of embodiments within the scope of the appended claims are described below. It will be apparent that the aspects described herein can be embodied in a wide variety of forms, and any particular structure and / or function described herein is merely illustrative. Based on this application, those skilled in the art will understand that one aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, any number of aspects set forth herein can be used to implement the device and / or practice the method. Additionally, this device and / or method can be implemented using structures and / or functionalities other than one or more of the aspects set forth herein.
[0026] It should also be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this application. The illustrations only show the components related to this application and are not drawn according to the number, shape and size of the components in actual implementation. In actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.
[0027] Furthermore, specific details are provided in the following description to facilitate a thorough understanding of the examples. However, those skilled in the art will understand that the described aspects can be practiced without these specific details.
[0028] This application provides a method for processing a high-temperature alloy integral bladed disk. The integral bladed disk of this application is made of GH4169D material, the blank is a die forging, the blade length is 26.06mm, the blade width is 1.12mm, and the minimum gap between the blades is 8.6mm.
[0029] Figures 1 to 3 As shown, a method for processing a high-temperature alloy integral bladed disk includes: Step 1: Roughly turn the outline of the integral bladed disk blank to obtain the rough-turned part; Step 2: Machining positioning holes 4 on the rough-machined part to determine the angular direction of blade 2 in subsequent steps; Step 3: Rough milling of the rough-machined parts. During rough milling, remove all the burrs between the blades and leave machining allowance at the blade 2 part. Step 4: Perform corrosion resistance inspection and vacuum stress relief heat treatment on the rough-milled parts in sequence, and repair the reference of the rough-milled parts. Step 5: The rough milled part of Step 4 is milled in the following order: plunge milling of the leading edge, plunge milling of the trailing edge, milling of the blade tip 3, layered spiral milling of the blade shape 2, finish milling of the flow channel, and root cleaning. The blade shape of the finish milled part is consistent with the dimensions of the theoretical blade shape of the part. Step 6: Perform precision turning on the disc body 1 part of the precision milled part.
[0030] In step 1, the disc body 1 of the rough-machined part has a 1.5mm margin compared to the theoretical disc body 1 of the part, the blade shape 2 of the rough-machined part has a 1mm margin compared to the theoretical blade shape 2 of the part, and the blade tip 3 of the rough-machined part has a 0.5mm margin compared to the theoretical blade tip 3 of the part.
[0031] In step 3, the machining allowance left for blade part 2 is 0.5mm, which is the allowance left for corrosion inspection and vacuum stress relief heat treatment.
[0032] In step 5, the specific methods for milling the leading edge, trailing edge, blade tip, finish milling the flow channel, and root cleaning are conventional existing technologies. The innovation of this application is the layered spiral milling of the blade profile 2. The method for layered spiral milling of the blade profile 2 is as follows: Create a multi-layered helical milling toolpath from the blade tip 3 to the blade root. The innermost helical milling toolpath mills the blade profile 2 part to conform to the theoretical blade profile 2 design of the part. For two adjacent helical milling toolpaths, the outer helical milling toolpath leads the inner helical milling toolpath by a certain number of revolutions. For any two adjacent helical milling toolpaths, the outer helical milling toolpath leads the inner helical milling toolpath by the same number of revolutions. The cutting amount of the innermost helical milling toolpath is 0.07-0.1mm, and the cutting amount of all other helical milling toolpaths is 0.2-0.3mm.
[0033] This application employs layered helical milling for finish milling of blade section 2. The layered helical milling strategy uses two or more helical milling toolpaths at the same radial height. The innermost layer is for finish milling, with a cutting allowance of 0.07-0.1 mm. The spindle speed and feed rate are relatively high for finish milling. Toolpaths outside the innermost layer are for rough milling, with a cutting allowance of 0.2-0.3 mm per layer. The spindle speed and feed rate are relatively slow during rough milling. The number of directional layers in the toolpaths for rough and finish milling are the same, but the toolpaths closer to the inner edge are processed later than the outer edges. For example, in a layered helical milling program with three helical toolpaths, the outermost toolpath might lead the middle layers by several revolutions when milling radially from the blade tip 3 to the blade root. The middle layer toolpaths, in turn, lead the innermost layer by the same number of revolutions. This strategy ensures that the tool does not contact the transition radius left by the outer milling when milling the inner edge, ultimately preventing the tool from prematurely failing due to excessive cutting depth.
[0034] Step 2 of this application removes the burrs between the blades, which reduces tool wear during finish milling and improves machining efficiency. After step 2, the subsequent step is finish milling the airfoil of a single blade. To avoid blade deformation during finish milling, this application designs a layered helical milling strategy in step 5. While finish milling the airfoil 2 part near the blade tip 3, the blade root part still has allowance. At this time, the blade root part has a larger volume, and the blade has sufficient rigidity, thereby reducing blade deformation during finish milling of airfoil 2. The combination of steps 2 and 5 in this application reduces blade deformation during finish milling of airfoil 2 while reducing tool wear and improving machining efficiency.
[0035] During the layered helical milling of blade section 2, a three-layer helical milling toolpath was created from the blade tip 3 to the blade root. The outermost helical milling toolpath had a cutting depth of 0.2 mm, the middle helical milling toolpath had a cutting depth of 0.2 mm, and the innermost helical milling toolpath had a cutting depth of 0.1 mm. The outer helical milling toolpath led the inner helical milling toolpath by 4 revolutions.
[0036] In step 5, a D8R3 tapered ball end mill is used to perform layered helical milling of the blade shape 2. The spindle speed of the innermost helical milling toolpath is 4509 rpm, and the feed rate is set to 541 mm / min. The spindle speed of the other helical milling toolpaths is 1646 rpm, and the feed rate is set to 40% of the feed rate of the innermost helical milling toolpath.
[0037] In step 6, after the precision-milled part is clamped by the vertical lathe machining fixture, the disc body 1 part of the precision-milled part is precision-machined. The vertical lathe fixture includes a positioning structure 6 and an adjustable auxiliary support structure 7. The positioning structure 6 is used to cooperate with the positioning hole 4 on the precision-milled part. The support end of the adjustable auxiliary support structure 7 is used to support and abut against the side of the disc body 1 facing away from the machining surface near the center during the precision machining of the disc body 1 part. In this embodiment, the area corresponding to the disc body 1 and the support end of the adjustable auxiliary support structure 7 is the annular plane 5 of the outer edge of the center hole of the disc body 1. The adjustable auxiliary support structure 7 includes a bolt and a rotating block. The bolt is threadedly connected to the base of the vertical lathe machining fixture. The rotating block is rotatably mounted on the end of the bolt's thread and directly contacts the part. The bolt is used to adjust the supporting force of the rotating block on the part. This application adds an auxiliary support with an adjustable height according to the actual situation of the part at the spoke position, which is prone to machining deformation. This ensures that the part, with the positioning reference as the reference surface, can freely deform and rebound according to the force when subjected to cutting force, thus preventing the part from collapsing and warping when cutting force occurs between the rigid auxiliary support and the positioning reference. In other embodiments, the adjustable auxiliary support structure 7 may consist only of a bolt, or a nut may be threadedly connected to the outer circumference of the nut. After adjusting the position of the bolt, rotating the nut abuts against the base of the vertical lathe machining fixture to lock the position of the bolt.
[0038] The steps for finish turning the disc body 1 of the precision-milled part include: semi-finish turning both ends of the disc body 1 until the allowance of the disc body 1 is 0.5mm; finish turning both ends of the semi-finish-turned disc body 1 to remove the remaining 0.5mm allowance. In order to reduce the allowance removed during turning and to ensure uniform stress on both sides of the part, this application includes a semi-finish turning process before the finish turning process. This strategy can also improve the deformation of the part under stress.
[0039] When precision turning disc 1, the step difference dimension of the part's spokes needs to be detected for each machining program to identify the deformation of the part. After each surface is machined, it is flipped over. After multiple flips during semi-precision turning and precision turning, the part can be machined with minimal deformation.
[0040] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.
Claims
1. A method for processing a high-temperature alloy integral bladed disk, characterized in that, include: Step 1: Roughly turn the outline of the integral bladed disk blank to obtain the rough-turned part; Step 2: Machining positioning holes on the rough-machined part to determine the blade angle direction in subsequent steps; Step 3: Rough milling of the rough-machined parts. During rough milling, remove all the burrs between the blades and leave machining allowance in the blade area. Step 4: Perform corrosion resistance inspection and vacuum stress relief heat treatment on the rough-milled parts, and repair the reference datum of the rough-milled parts; Step 5: The rough milled part from Step 4 is milled in the following order: plunge milling of the leading edge, plunge milling of the trailing edge, milling of the blade tip, layered spiral milling of the blade shape, finish milling of the flow channel, and root cleaning. The blade shape of the finish milled part is consistent with the dimensions of the theoretical blade shape of the part. Step 6: Perform precision turning on the disc body part of the precision-milled part.
2. The processing method of the high-temperature alloy integral bladed disk according to claim 1, characterized in that, In step 1, the rough-machined part has a 1.5mm margin compared to the theoretical disc size, the rough-machined part has a 1mm margin compared to the theoretical blade size, and the rough-machined part has a 0.5mm margin compared to the theoretical blade tip.
3. The processing method of the high-temperature alloy integral bladed disk according to claim 1, characterized in that, In step 3, the machining allowance for the blade-shaped part is 0.5mm.
4. The processing method of the high-temperature alloy integral bladed disk according to claim 1, characterized in that, In step 5, the method for layered spiral milling of the blade-shaped portion is as follows: Create a multi-layered helical milling toolpath from the blade tip to the blade root. The innermost helical milling toolpath mills the blade profile to conform to the theoretical blade profile design of the part. For two adjacent helical milling toolpaths, the outer helical milling toolpath leads the inner helical milling toolpath by a certain number of revolutions. For any two adjacent helical milling toolpaths, the outer helical milling toolpath leads the inner helical milling toolpath by the same number of revolutions. The cutting amount of the innermost helical milling toolpath is 0.07-0.1 mm, and the cutting amount of all other helical milling toolpaths is 0.2-0.3 mm.
5. The processing method of the high-temperature alloy integral bladed disk according to claim 4, characterized in that, During the layered helical milling of the blade section, a three-layer helical milling toolpath is created from the blade tip to the blade root. The outermost helical milling toolpath has a cutting amount of 0.2 mm, the middle helical milling toolpath has a cutting amount of 0.2 mm, and the innermost helical milling toolpath has a cutting amount of 0.1 mm.
6. The processing method of the high-temperature alloy integral bladed disk according to claim 4, characterized in that, The outer spiral milling toolpath leads the inner spiral milling toolpath by 4 revolutions.
7. The processing method of the high-temperature alloy integral bladed disk according to claim 4, characterized in that, In step 5, a D8R3 tapered ball end mill is used to perform layered helical milling of the blade-shaped part. The spindle speed of the innermost helical milling toolpath is 4509 rpm, and the feed rate is set to 541 mm / min. The spindle speed of the other helical milling toolpaths is 1646 rpm, and the feed rate is set to 40% of the feed rate of the innermost helical milling toolpath.
8. The processing method of the high-temperature alloy integral bladed disk according to claim 1, characterized in that, Step 6, the step of precision turning the disc body portion of the precision-milled part includes: Semi-finish machining is performed on both ends of the disc until the remaining material of the disc is 0.5mm; The two ends of the semi-finished disc are then finished to remove the remaining 0.5mm allowance.
9. The processing method of the high-temperature alloy integral bladed disk according to claim 1, characterized in that, In step 6, after the precision-milled part is clamped by the vertical lathe machining fixture, the disc part of the precision-milled part is precision-machined. The vertical lathe fixture includes a positioning structure and an adjustable auxiliary support structure. The positioning structure is used to cooperate with the positioning hole on the precision-milled part. The support end of the adjustable auxiliary support structure is used to face the end face near the center on the side of the disc part that is opposite to the machining surface during the precision machining of the disc part.