A vane linear friction welding top forging posture calibration device and method

Abstract

The present application belongs to the technical field of welding, and particularly relates to a kind of vane linear friction welding upset posture calibration device and method.The device includes base and vane upset unit, wheel disc posture adjustment unit, robot and three coordinate measuring system arranged on the base, wheel disc posture adjustment unit is used for wheel disc clamping and posture adjustment, vane upset unit is used for vane clamping, servo upset and linear friction welding;Robot is used for taking and placing calibration sheet, and calibration sheet and wheel disc friction interface are attached to produce plastic indentation when upsetting;Three coordinate measuring system detects indentation depth on calibration sheet through three coordinate measuring probe, obtains friction interface pressure distribution, and controls wheel disc posture adjustment unit with friction interface pressure uniformity as target, determines welding starting calibration posture.The present application improves joint quality and fatigue performance, reduces post-weld processing and material consumption, is compatible with existing linear friction welding equipment, and is suitable for high-performance wheel disc / vane rotor component batch manufacturing.

Description

Technical Field

[0001] This invention belongs to the field of welding technology, and specifically relates to a device and method for calibrating the upsetting attitude of blades in linear friction welding. Background Technology

[0002] Linear friction welding (LFW) is a key process in the manufacturing of integral bladed disks for aero-engines. The contact pressure at the friction interface during the initial welding stage plays a decisive role in the weld quality. Blades are complex spatial curved surface components, and the welded end face of the disk has errors such as flatness, waviness, machining texture, and local steps. This results in severely uneven pressure distribution at the friction interface when the blade and disk are in contact at the designed attitude. Uneven pressure can lead to instability in the interfacial friction coefficient and heat generation, plastic flow bias, and induce local incomplete welding, crack initiation, and fluctuations in mechanical properties. Excessively high local temperatures can also cause grain coarsening, significantly reducing the bending fatigue strength at the blade root, resulting in poor weld quality consistency and low yield.

[0003] Existing linear friction welding (LFW) equipment mostly uses fixed posture clamping, lacks the ability to calibrate and adaptively adjust the upsetting posture before welding, and cannot convert interface error into a quantifiable pressure uniformity index and perform closed-loop correction, making it difficult to meet the needs of mass production of high-performance integral bladed disks. Summary of the Invention

[0004] To address the aforementioned problems, the present invention aims to provide a blade linear friction welding upsetting attitude calibration device and method, thereby solving the problem that existing linear friction welding equipment lacks the ability to calibrate and adaptively adjust the upsetting attitude before welding, making it difficult to meet the needs of mass production of high-performance integral bladed disks.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] This invention provides a blade linear friction welding upsetting attitude calibration device, including a base and a blade upsetting unit, a wheel attitude adjustment unit, a robot, and a coordinate measuring system disposed on the base. The blade upsetting unit and the wheel attitude adjustment unit are arranged opposite to each other. The wheel attitude adjustment unit is used for wheel mounting and attitude adjustment, while the blade upsetting unit is used for blade mounting, servo upsetting, and linear friction welding. The robot is used to automatically pick up and place calibration pieces, which are used to fit against the friction interface of the wheel and generate plastic indentations during upsetting. The coordinate measuring system uses a coordinate measuring probe to detect the indentation depth on the calibration pieces at multiple points, obtains the pressure distribution information of the friction interface of the wheel, and controls the wheel attitude adjustment unit with the pressure uniformity of the friction interface of the wheel as the target, ultimately determining the welding start calibration attitude of the wheel.

[0007] The coordinate measuring probe is mounted on a support frame.

[0008] The calibration plate is made of soft metal.

[0009] The wheel attitude adjustment unit includes a hydraulic servo six-degree-of-freedom parallel adjustment mechanism, a rigid disk, a wheel fixture, and a machine vision system. The hydraulic servo six-degree-of-freedom parallel adjustment mechanism is mounted on the base and its output end is connected to the rigid disk. The wheel fixture is mounted on the rigid disk and is used to mount the wheel. The machine vision system is mounted on the wheel fixture and is used to monitor the temperature and shape of the flash during linear friction welding (LFW) in real time.

[0010] The hydraulic servo six-degree-of-freedom parallel adjustment mechanism includes a static platform, a moving platform, and three sets of servo drives. The static platform is mounted on the base, and three sets of servo drives are evenly distributed along the circumference of the static platform. The output ends of the three sets of servo drives are all connected to the moving platform. The position and posture of the moving platform are adjusted by the coordinated action of the multiple sets of servo drives. The rigid disk is connected to the moving platform.

[0011] Each servo drive group includes two servo hydraulic cylinders. The tail of the servo hydraulic cylinder is connected to the static platform, and the output end of the servo hydraulic cylinder is hinged to the moving platform.

[0012] The blade upsetting unit includes a hydraulic servo upsetting mechanism, a blade tooling, a vibration table, a hydraulic vibrator, and a horizontal platform. The hydraulic servo upsetting mechanism includes a servo upsetting hydraulic cylinder, guide column I, and guide column II. The servo upsetting hydraulic cylinder is horizontally mounted on the base, and its output end is connected to the horizontal platform. Guide column I and guide column II are horizontally mounted on both sides of the horizontal platform, and guide column I and guide column II are slidably engaged with the base. The vibration table is mounted on the horizontal platform and can slide along a direction perpendicular to the output direction of the servo upsetting hydraulic cylinder. The hydraulic vibrator is mounted on the horizontal platform, and its output end is connected to the vibration table. The hydraulic vibrator is used to drive the vibration table to reciprocate.

[0013] The blade tooling is a split structure, including blade tooling I and blade tooling II. After blade tooling I and blade tooling II are molded together, a contour cavity matching the outer contour of the blade is formed. The outer end of the contour cavity is provided with a flash contour surface, which is used to form the forging fillet and flash at the root of the blade.

[0014] Another aspect of the present invention provides a method for calibrating the upsetting attitude of a blade based on the device described above during linear friction welding, comprising the following steps:

[0015] Step S1: Mount the wheel and blade onto the wheel fixture and blade fixture respectively;

[0016] Step S2: The robot places the calibration piece on the friction interface to be welded on the wheel;

[0017] Step S3: The hydraulic servo upsetting mechanism applies upsetting force to make the blade fit against the calibration plate, forming an indentation on the calibration plate;

[0018] Step S4: The coordinate measuring system detects the spatial position and attitude information of the wheel by using a coordinate measuring probe to check the calibration plate;

[0019] Step S5: The coordinate measuring system detects the calibration plate by measuring the depth of the indentation on the calibration plate at multiple points using the coordinate measuring probe, thereby obtaining the pressure distribution information of the friction interface of the wheel. The hydraulic servo six-degree-of-freedom parallel adjustment mechanism is controlled with the pressure uniformity of the friction interface of the wheel as the target, thereby adjusting the relative attitude of the wheel.

[0020] Step S6: Replace the calibration piece and repeat steps S2 to S4 until the indentation depth on the calibration piece is uniform, and determine the welding start calibration posture.

[0021] Step S7: Perform linear friction welding.

[0022] In step S7, linear friction welding includes the following steps:

[0023] Initial friction: The vibration table vibrates at low amplitude and low frequency, and the hydraulic servo upsetting mechanism gradually applies upsetting force, resulting in slight plastic deformation of the friction interface between the blade and the wheel.

[0024] Stable friction: By increasing the amplitude and frequency of the vibration table, a high-temperature plastic layer is formed at the friction interface between the blade and the wheel, and the flash is extruded stably;

[0025] Vibration-stopping upsetting and attitude change: After the vibration table stops vibrating and the machine vision determines that the flash is qualified, the hydraulic servo six-degree-of-freedom parallel adjustment mechanism smoothly transitions the wheel from the calibrated attitude to the design attitude. The hydraulic servo upsetting mechanism maintains the upsetting force and reaches the process position. The pressure holding completes the diffusion welding and recrystallization, and finally forms a high-strength solid welded joint.

[0026] The present invention has the following beneficial effects and advantages:

[0027] 1. Uniform and controllable pressure: This invention quantifies the pressure distribution through calibration plate indentation and uses a hydraulic servo six-degree-of-freedom parallel adjustment mechanism for closed-loop adjustment, which solves the problem of uneven pressure at the initial interface from the root, suppresses incomplete welding, cracks, and grain coarsening, and improves fatigue performance and welding consistency.

[0028] 2. Intelligent closed-loop control: This invention integrates three-coordinate measurement, machine vision and six-degree-of-freedom adjustment to achieve automatic calibration and adaptive correction, support digital twin and process closed loop, reduce human intervention and improve the level of automation.

[0029] 3. Significant cost reduction and efficiency improvement: The blade tooling of the present invention forms root forging fillet and two-dimensional flash, eliminating the need for three-dimensional curved surface machining after welding, greatly reducing the blank thickness, saving materials and five-axis machining time, and showing outstanding cost advantages.

[0030] 4. Excellent structural rigidity: The hydraulic servo six-degree-of-freedom parallel mechanism of the present invention has better rigidity than a serial five-axis machine tool, with strong load-bearing capacity, high posture adjustment accuracy, and is suitable for high temperature and high pressure welding conditions of titanium alloys.

[0031] 5. Strong process compatibility: This invention is seamlessly compatible with the pressure loading and vibration system of existing linear friction welding equipment, and can be upgraded without changing the main structure, making it convenient for engineering applications.

[0032] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings.

[0033] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0034] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0035] Figure 1 Axonometric view of a blade linear friction welding upsetting attitude calibration device of the present invention;

[0036] Figure 2 for Figure 1 Enlarged view of a portion of point A in the middle;

[0037] Figure 3 for Figure 2 Enlarged view of a portion of point B in the middle;

[0038] Figure 4 A longitudinal cross-sectional schematic diagram of a blade linear friction welding upsetting attitude calibration device according to the present invention;

[0039] Figure 5 for Figure 4 Enlarged view of a portion of point D;

[0040] Figure 6 This is a partial structural schematic diagram of the blade upsetting unit in this invention;

[0041] Figure 7 for Figure 6 A magnified view of a portion of point E in the middle.

[0042] In the diagram: 1. Base; 2. Hydraulic servo upsetting mechanism; 201. Guide column I; 202. Guide column II; 203. Servo upsetting hydraulic cylinder; 3. Hydraulic servo six-degree-of-freedom parallel adjustment mechanism; 301. Static platform; 302. Moving platform; 303. Servo hydraulic cylinder; 4. Rigid disc; 5. Wheel disc fixture; 6. Wheel disc; 7. Blade; 701. Blade root; 8. Blade fixture; 801. Blade fixture I; 802. Blade fixture II; 8 03. Internal contouring cavity I; 804. Internal contouring cavity II; 805. Parting surface I; 806. Parting surface II; 807. External contouring surface I; 808. External contouring surface II; 809. Root chamfering surface I; 810. Root chamfering surface II; 9. Vibration table; 10. Hydraulic vibrator; 11. Horizontal platform; 12. Calibration plate; 13. Robot; 14. Coordinate measuring system; 15. Coordinate measuring probe; 16. Machine vision. Detailed Implementation

[0043] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0044] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0045] See Figures 1 to 7 As shown, an embodiment of the present invention provides a blade linear friction welding upsetting attitude calibration device, including a base 1 and a blade upsetting unit, a wheel attitude adjustment unit, a robot 13, and a three-coordinate measurement system 14 disposed on the base 1. The blade upsetting unit and the wheel attitude adjustment unit are arranged opposite to each other. The wheel attitude adjustment unit is used for mounting and adjusting the attitude of the wheel 6, and the blade upsetting unit is used for mounting, servo upsetting, and linear friction welding of the blade 7. The robot 13 is used to automatically pick up and place the calibration piece 12. The calibration piece 12 is used to fit with the friction interface of the wheel 6 and generate a plastic indentation during upsetting. The three-coordinate measurement system 14 detects the indentation depth on the calibration piece 12 at multiple points through the three-coordinate measurement probe 15 to obtain the pressure distribution information of the friction interface of the wheel 6, and controls the wheel attitude adjustment unit with the pressure uniformity of the friction interface of the wheel 6 as the target, and finally determines the welding start calibration attitude of the wheel 6.

[0046] Specifically, the coordinate measuring probe 15 is mounted on the support frame. The calibration plate 12 is made of a soft metal sheet with a hardness significantly lower than that of the wheel 6 and the blade 7, so only the calibration plate 12 produces plastic indentations during upsetting.

[0047] See Figure 1 and Figure 2 As shown, in an embodiment of the present invention, the wheel attitude adjustment unit includes a hydraulic servo six-degree-of-freedom parallel adjustment mechanism 3, a rigid disk 4, a wheel fixture 5, and a machine vision system 16. The hydraulic servo six-degree-of-freedom parallel adjustment mechanism 3 is mounted on the base 1, and its output end is connected to the rigid disk 4. The wheel fixture 5 is mounted on the rigid disk 4 and is used to mount the wheel 6. The machine vision system 16 is mounted on the wheel fixture 5 and is used to monitor the temperature and shape of the flash during linear friction welding in real time.

[0048] In an embodiment of the present invention, the hydraulic servo six-degree-of-freedom parallel adjustment mechanism 3 includes a static platform 301, a moving platform 302, and three sets of servo drives. The static platform 301 is mounted on the base 1, and three sets of servo drives are evenly distributed along the circumference of the static platform 301. The output ends of the three sets of servo drives are all connected to the moving platform 302. The position and posture of the moving platform 302 are adjusted under the coordinated action of the multiple sets of servo drives. The rigid disk 4 is connected to the moving platform 302.

[0049] Specifically, each servo drive includes two servo hydraulic cylinders 303. The tail of each servo hydraulic cylinder 303 is connected to the stationary platform 301, and the output end of each servo hydraulic cylinder 303 is hinged to the moving platform 302. The six servo hydraulic cylinders 303 can adjust the six degrees of freedom of the moving platform 302 relative to the stationary platform 301 online, thereby adjusting the position and orientation of the wheel 6 and blades 7 according to welding process requirements. The wheel fixture 5 can index and fix N rotation angles of the wheel 6, thereby enabling linear friction welding of N blades 7.

[0050] See Figure 1 and Figure 2As shown, in an embodiment of the present invention, the blade upsetting unit includes a hydraulic servo upsetting mechanism 2, a blade tooling 8, a vibration table 9, a hydraulic vibrator 10, and a platform 11. The hydraulic servo upsetting mechanism 2 includes a servo upsetting hydraulic cylinder 203, guide column I 201, and guide column II 202. The servo upsetting hydraulic cylinder 203 is horizontally mounted on the base 1, and its output end is connected to the platform 11. The servo upsetting hydraulic cylinder 203 drives the platform 11 to move linearly along the radial direction of the wheel 6. Guide columns I 201 and II 202 are horizontally mounted on both sides of the platform 11, and these guide columns I 201 and II 202 are slidably engaged with the base 1. The vibration table 9 is mounted on the platform 11 and can slide in a direction perpendicular to the output direction of the servo upsetting hydraulic cylinder 203, i.e., the vibration table 9 can move along the axial direction of the wheel 6. The hydraulic vibrator 10 is mounted on the platform 11, and its output end is connected to the vibration table 9. The hydraulic vibrator 10 drives the vibration table 9 to reciprocate.

[0051] See Figures 4 to 7 As shown in the embodiment of the present invention, the blade fixture 8 is a split structure, including blade fixture I 801 and blade fixture II 802. Blade fixture I 801 and blade fixture II 802 are fixed to the vibration table 9 by screws. After the blade fixture I 801 and blade fixture II 802 are closed, they form a contouring cavity that matches the outer contour of the blade 7. The outer end of the contouring cavity is provided with a flash contouring surface, which is used to form the forging fillet and flash at the root of the blade. Therefore, the blade fixture 8, through the internal contouring cavity, parting surface, root chamfering shaping surface and outer contouring surface, realizes precise blade clamping, root forging fillet forming and two-dimensional flash control.

[0052] Specifically, blade tooling I 801 has an internal contouring cavity I 803, a parting surface I 805, an outer contouring surface I 807, and a root chamfering surface I 809; blade tooling II 802 has an internal contouring cavity II 804, a parting surface II 806, an outer contouring surface II 808, and a root chamfering surface II 810; after mold closing, parting surface I 805 and parting surface II 806 fit together, and internal contouring cavity I 803 and internal contouring cavity II 804 enclose to form a complete contouring cavity; except for the blade root 701, the rest of the blade 7 is contained within the contouring cavity. The root chamfering shaping surface I 809 and the root chamfering shaping surface II 810 form a closed loop root chamfering shaping surface, which is used to form the forging fillet between the blade root 701 and the wheel 6; the outer contouring surface I 807 and the outer contouring surface II 808 are located outside the root chamfering shaping surface and form a closed loop flash contouring surface, which is used to form a micro-gap forging flash surface opposite to the blade 7.

[0053] Specifically, the calibration plate 12 is preferably made of aluminum. For example, grade 1060 is selected, with a Brinell hardness of 25-32 HB, while the Brinell hardness of titanium alloy blades and discs is 320-380 HB. Therefore, when the robot 13 places the calibration plate 12 between the disc 6 and the blade 7, the calibration plate 12 will have plastic deformation indentations only under the action of the upsetting force, while the disc 6 and the blade 7 will not have plastic deformation. The coordinate measuring system 14 uses the coordinate measuring probe 15 to measure the depth of the indentations at multiple points on the calibration plate 12, thereby obtaining the relative posture of the disc 6 and the blade 7 under the upsetting force to determine whether the pressure is uniform.

[0054] Specifically, the disk 6 includes disk rotor components such as a fan disk, a compressor disk, and a turbine disk. The blades 7 include components such as fan blades, compressor blades, and turbine blades.

[0055] This invention eliminates the need for post-linear friction welding three-dimensional surface machining, thereby minimizing the thickness of the blade forging blank and saving significant amounts of raw materials. It also eliminates the need for post-weld five-axis CNC machining, significantly reducing material costs and five-axis CNC machining expenses. The calibration plate 12 and related supporting mechanisms acquire the pressure distribution matrix during the welding process and calculate the pressure uniformity index. When the pressure uniformity reaches a set threshold, the system outputs a "welding start allowed" signal; if the threshold is not reached, welding is prohibited, ensuring the stability and reliability of the welding process. The calibration plate 12 and related mechanisms work in conjunction with the hydraulic servo six-degree-of-freedom parallel adjustment mechanism to form a composite structure of "multi-point floating + fine-tuning execution," enabling adaptive fitting of the welding end face under small angle and small warpage errors, further ensuring welding accuracy. Compared to the commonly used serial five-axis linkage CNC machining centers, the hydraulic servo six-degree-of-freedom parallel adjustment mechanism has a significant stiffness advantage and is more suitable for high-precision linear friction welding scenarios. The machine vision system 16 has the functions of flash shape perception and thermal feature sensing, which can accurately control the linear friction welding process. Specifically, it can calibrate the flash shape of the blade and the disk, the gradual change process of their relative posture, and the gradual change process of their relative position during the upsetting process, providing accurate data support for welding process optimization.

[0056] The present invention provides a blade linear friction welding upsetting attitude calibration device, which forms a controllable compressive stress field at the friction interface during the welding process and meets the pressure uniformity index; it converts the friction interface error into a quantifiable index, such as pressure uniformity / fitness, and automatically adjusts when the index is not met; it is compatible with the pressure loading system of the linear friction welding equipment to ensure the stability of the welding start boundary conditions.

[0057] See Figures 1 to 7 As shown, another embodiment of the present invention provides a method for calibrating the upsetting attitude of a blade based on the device described above, comprising the following steps:

[0058] Step S1: Mount the wheel 6 and blade 7 onto the wheel fixture 5 and blade fixture 8 respectively;

[0059] Step S2: Robot 13 attaches calibration sheet 12 to the friction interface to be welded on wheel 6; in this embodiment, calibration sheet 12 is an aluminum sheet of equal thickness;

[0060] Step S3: The hydraulic servo upsetting mechanism 2 moves forward to apply upsetting force, so that the blade 7 fits against the calibration plate 12 and forms an indentation on the calibration plate 12. Then the hydraulic servo upsetting mechanism 2 moves backward.

[0061] Step S4: The coordinate measuring system 14 uses the coordinate measuring probe 15 to mark at least six points on the wheel 6 to determine the spatial position and orientation of the wheel 6;

[0062] Step S5: The depth of the indentation on the calibration plate 12 is detected by the three-coordinate measuring probe 15 at multiple points (e.g., 100 points) to obtain the uniformity information of the indentation on the calibration plate 12, thereby obtaining the pressure distribution information of the friction interface of the wheel 6. The hydraulic servo six-degree-of-freedom parallel adjustment mechanism 3 is controlled with the pressure uniformity of the friction interface of the wheel 6 as the target, thereby adjusting the relative attitude of the wheel 6.

[0063] Step S6: Replace calibration piece 12 and repeat steps S2 to S4 until the indentation depth on calibration piece 12 is uniform, and determine the welding start calibration posture.

[0064] Step S7: Perform linear friction welding.

[0065] In step S7, linear friction welding includes the following steps:

[0066] Initial friction: The friction interface between blade 7 and disk 6 initially contacts, and the hydraulic vibrator 10 drives the vibration table 9 to vibrate linearly at low amplitude and low frequency. The frictional heat rises slowly, and the friction interface undergoes slight plastic deformation. The hydraulic servo upsetting mechanism 2 gradually applies upsetting force. In the unstable friction stage, the amplitude and frequency of the vibration table 9 increase, the frictional heat increases significantly, the temperature of the friction interface rises rapidly, and local adhesion and shearing phenomena occur. At this time, there is no obvious deformation of disk 6 and blade 7 in the radial direction of disk 6.

[0067] Stable friction: By increasing the amplitude frequency of the vibration table 9, a high-temperature plastic layer is formed at the friction interface between the blade 7 and the wheel 6, and the flash is stably extruded; at this time, the wheel 6 and the blade 7 are significantly shortened in the turbine radial direction, and the temperature and deformation reach dynamic equilibrium.

[0068] Vibration-stopping upsetting and attitude change: Vibration table 9 stops vibrating. After machine vision 16 determines that the flash is qualified, hydraulic servo six-degree-of-freedom parallel adjustment mechanism 3 smoothly transitions wheel 6 from the calibrated attitude to the design attitude. Hydraulic servo upsetting mechanism 2 maintains the upsetting force and reaches the process position. Pressure holding completes diffusion welding and recrystallization, and finally forms a high-strength solid welded joint.

[0069] In the embodiments of this invention, by using data fed back from a machine vision system to optimize welding process parameters and iterate repeatedly, the mechanical properties of the weld can be optimized to achieve the best state. This data can directly guide the precise adjustment of process parameters. This method can effectively avoid the problem of local crystallization and coarsening caused by uneven pressure and uneven temperature field distribution in linear friction welding, thereby solving the technical pain point of unstable blade fatigue life. The blade and the root of the impeller are forged with rounded corners, which have complete forging streamlines; the outer contoured surface is used to form a micro-gap with the impeller to forge a flash surface. This invention adopts a two-dimensional flash design.

[0070] In the embodiments of the present invention, the hydraulic servo six-degree-of-freedom parallel adjustment mechanism 3 is a key component for realizing intelligent linear friction welding. This mechanism, combined with a machine vision system, can automatically identify weld seam offset and correct the welding trajectory in real time, effectively improving welding accuracy and consistency. Furthermore, by collecting sensor data, a digital twin model of the welding process can be constructed, enabling closed-loop control of the entire welding process, reducing human intervention, and thereby improving production efficiency, weld seam reliability, overall welding quality, and automation level.

[0071] In summary, this invention discloses a blade linear friction welding upsetting attitude calibration device and method for welding integral titanium alloy bladed disks. It employs a soft calibration plate for upsetting and imprinting, and uses a three-coordinate measuring machine to uniformly measure the indentation and quantify the interface pressure distribution. A six-degree-of-freedom mechanism is used for closed-loop adjustment to achieve a uniform attitude. During welding, the blade smoothly transitions from the calibration attitude to the designed attitude, and a dedicated blade tooling is used to achieve root forging fillet and two-dimensional flash forming. This invention solves problems such as incomplete welding, cracks, and grain coarsening caused by uneven interface pressure at the start of linear friction welding, improves joint quality and fatigue performance, significantly reduces post-weld processing and material consumption, is compatible with existing linear friction welding equipment, and is suitable for mass production of high-performance integral bladed disks.

[0072] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A device for calibrating the upsetting attitude of a blade in linear friction welding, characterized in that, The system includes a base (1) and a blade upsetting unit, a wheel attitude adjustment unit, a robot (13), and a coordinate measuring system (14) set on the base (1). The blade upsetting unit and the wheel attitude adjustment unit are arranged opposite to each other. The wheel attitude adjustment unit is used for mounting and adjusting the attitude of the wheel (6). The blade upsetting unit is used for mounting, servo upsetting, and linear friction welding of the blade (7). The robot (13) is used to automatically pick up and place the calibration piece (12). The calibration piece (12) is used to fit with the friction interface of the wheel (6) and generate plastic indentation during upsetting. The coordinate measuring system (14) uses the coordinate measuring probe (15) to detect the indentation depth on the calibration piece (12) at multiple points, obtains the pressure distribution information of the friction interface of the wheel (6), and controls the wheel attitude adjustment unit with the pressure uniformity of the friction interface of the wheel (6) as the target, and finally determines the welding start calibration attitude of the wheel (6).

2. The blade linear friction welding upsetting attitude calibration device according to claim 1, characterized in that, The coordinate measuring probe (15) is mounted on the support frame.

3. The blade linear friction welding upsetting attitude calibration device according to claim 1, characterized in that, The calibration plate (12) is made of soft metal.

4. The blade linear friction welding upsetting attitude calibration device according to claim 1, characterized in that, The wheel attitude adjustment unit includes a hydraulic servo six-degree-of-freedom parallel adjustment mechanism (3), a rigid disk (4), a wheel fixture (5), and a machine vision (16). The hydraulic servo six-degree-of-freedom parallel adjustment mechanism (3) is set on the base (1) and its output end is connected to the rigid disk (4). The wheel fixture (5) is set on the rigid disk (4) and is used to mount the wheel (6). The machine vision (16) is set on the wheel fixture (5) and is used to monitor the temperature and shape of the flash during the friction welding process in real time.

5. The blade linear friction welding upsetting attitude calibration device according to claim 4, characterized in that, The hydraulic servo six-degree-of-freedom parallel adjustment mechanism (3) includes a static platform (301), a moving platform (302), and three sets of servo drives. The static platform (301) is set on the base (1). Three sets of servo drives are evenly distributed along the circumference on the static platform (301). The output ends of the three sets of servo drives are all connected to the moving platform (302). The position and posture of the moving platform (302) are adjusted under the coordinated action of multiple sets of servo drives. The rigid disk (4) is connected to the moving platform (302).

6. The blade linear friction welding upsetting attitude calibration device according to claim 5, characterized in that, Each set of servo drives includes two servo hydraulic cylinders (303), the tail of which is connected to the stationary platform (301), and the output end of which is hinged to the moving platform (302).

7. The blade linear friction welding upsetting attitude calibration device according to claim 4, characterized in that, The blade upsetting unit includes a hydraulic servo upsetting mechanism (2), a blade tooling (8), a vibration table (9), a hydraulic vibrator (10), and a water platform (11). The hydraulic servo upsetting mechanism (2) includes a servo upsetting hydraulic cylinder (203), guide column I (201), and guide column II (202). The servo upsetting hydraulic cylinder (203) is horizontally mounted on the base (1), and the output end of the servo upsetting hydraulic cylinder (203) is connected to the water platform (11). The two sides are provided with guide pillar I (201) and guide pillar II (202), which are slidably engaged with the base (1); the vibration table (9) is set on the horizontal platform (11) and can slide along the output direction perpendicular to the servo upsetting hydraulic cylinder (203); the hydraulic vibrator (10) is set on the horizontal platform (11) and its output end is connected to the vibration table (9), and the hydraulic vibrator (10) is used to drive the vibration table (9) to reciprocate.

8. The blade linear friction welding upsetting attitude calibration device according to claim 7, characterized in that, The blade tooling (8) is a split structure, including blade tooling I (801) and blade tooling II (802). After the blade tooling I (801) and blade tooling II (802) are molded together, they form a contour cavity that matches the outer contour of the blade (7). The outer end of the contour cavity is provided with a flash contour surface, which is used to form the forging fillet and flash at the root of the blade.

9. A method for calibrating the upsetting attitude of blades in linear friction welding based on the device described in claim 8, characterized in that, Includes the following steps: Step S1: Mount the wheel (6) and blade (7) onto the wheel fixture (5) and blade fixture (8) respectively; Step S2: The robot (13) places the calibration piece (12) on the friction interface to be welded on the wheel (6); Step S3: The hydraulic servo upsetting mechanism (2) applies upsetting force to make the blade (7) fit against the calibration plate (12), and an indentation is formed on the calibration plate (12); Step S4: The coordinate measuring system detects the spatial position and attitude information of the wheel (6) by using the coordinate measuring probe (15) to detect the calibration plate (12). Step S5: The three-coordinate measuring system detects the calibration plate (12) by using the three-coordinate measuring probe (15) to detect the indentation depth on the calibration plate (12) at multiple points, obtains the pressure distribution information of the friction interface of the wheel (6), and controls the hydraulic servo six-degree-of-freedom parallel adjustment mechanism (3) with the pressure uniformity of the friction interface of the wheel (6) as the target, thereby adjusting the relative attitude of the wheel (6); Step S6: Replace the calibration piece (12) and repeat steps S2 to S4 until the indentation depth on the calibration piece (12) is uniform, and determine the welding start calibration posture; Step S7: Perform linear friction welding.

10. The method for calibrating the upsetting attitude of blades in linear friction welding according to claim 9, characterized in that, In step S7, linear friction welding includes the following steps: Initial friction: The vibration table (9) vibrates at low amplitude and low frequency, and the hydraulic servo upsetting mechanism (2) gradually applies upsetting force, causing slight plastic deformation of the friction interface between the blade (7) and the wheel (6); Stable friction: Increase the amplitude frequency of the vibration table (9), and a high-temperature plastic layer is formed at the friction interface between the blade (7) and the wheel (6), and the flash is stably extruded; Vibration-stopping upsetting and attitude change: The vibration table (9) stops vibrating. After the machine vision (16) determines that the flash is qualified, the hydraulic servo six-degree-of-freedom parallel adjustment mechanism (3) smoothly transitions the wheel (6) from the calibrated attitude to the design attitude. The hydraulic servo upsetting mechanism (2) maintains the upsetting force and reaches the process position. The pressure is maintained to complete the diffusion welding and recrystallization, and finally a high-strength solid welded joint is formed.

Images