整体叶盘通道去余量线切割加工技术研究
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摘要
整体叶盘的加工余量主要是在其通道开槽粗加工阶段去除的,合理选取整体叶盘粗加工通道余量去除方法是降低通道加工费用、实现整体叶盘加工经济性的关键。由于线切割机床加工单位成本低的原因,采用线切割加工方法对整体叶盘通道进行去余量加工。提出利用叶型与轮毂偏置面确定通道加工边界;通过比较通道边界投影后的投影面积大小确定最优矢量;然后根据最优矢量确定线切割丝与叶盘端面之间的夹角以及切割区域,实现整体叶盘粗加工阶段去除余量最大化。该方法可以有效地解决整体叶盘粗加工阶段经济性问题。试验表明,线切割加工可以应用在整体叶盘通道去余量加工中,并且与传统数控铣削相比,单个通道的加工费用仅为数控铣削加工费用的1/20。
Machining allowance for a blisk is mainly removed in the rough milling, so selecting the appropriate machining method toremove the allowance of blisk tunnel in the rough milling is key to reducing the tunnel cutting costs and making the blisk machiningeconomically. As the wire cut electrical discharge machining machine processing unit cost is low, wire cutting is used to remove theallowance of tunnel. The processing boundary of tunnel is determined by the offset surface of blade and hub of blisk.The optimalvector is determined by comparing the size of the projected area after the projection of the boundary of the tunnel. Then, the cuttingarea and the angle between the line cutting wire and the end face of the blisk are determined according to the optimal vector, and thecutting area is maximized. This method can effectively solve the economic problems of blisk in the rough milling. The demonstrationshows that the wire cutting can be applied to remove the allowance of blisk, and compared with the traditional CNC milling, theprocessing cost of a single channel is only one-twentieth of the cost of CNC milling.
Machining allowance for a blisk is mainly removed in the rough milling, so selecting the appropriate machining method toremove the allowance of blisk tunnel in the rough milling is key to reducing the tunnel cutting costs and making the blisk machiningeconomically. As the wire cut electrical discharge machining machine processing unit cost is low, wire cutting is used to remove theallowance of tunnel. The processing boundary of tunnel is determined by the offset surface of blade and hub of blisk.The optimalvector is determined by comparing the size of the projected area after the projection of the boundary of the tunnel. Then, the cuttingarea and the angle between the line cutting wire and the end face of the blisk are determined according to the optimal vector, and thecutting area is maximized. This method can effectively solve the economic problems of blisk in the rough milling. The demonstrationshows that the wire cutting can be applied to remove the allowance of blisk, and compared with the traditional CNC milling, theprocessing cost of a single channel is only one-twentieth of the cost of CNC milling.
引文
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[11]李湉,陈五一,陈彩红.整体叶轮插铣粗加工算法[J].计算机集成制造系统,2010,16(8):1696-1701.LI Tian,CHEN Wuyi,CHEN Caihong.Rough machining method for blink plunge milling[J].Computer Integrated Manufacturing Systems,2010,16(8):1696-1701.
[12]董雷,曹利新.通道曲面的柱面逼近方法及其在叶轮插铣中的应用[J].航空学报,2014,35(8):2331-2340.DONG L,CAO L X.Approximation method of tunnel surfaces with general cylindrical surfaces and its application in plunge milling of impellers[J].Acta Aeronautica et Astronautica Sinica,2014,35(8):2331-2340.
[13]BALA M,LAX P,SARMA S,et al.Generating 5-axis NC roughing paths directly from a tessellated representation[J].Computer-aided Design,2000,32(4):261-277.
[14]RISKO D G.DAVYDOV A D.Manufacturing applications and productivity limitations of electrochemical machining[J].Manufacturing Science and Engineering,1993,64:701-711.
[15]朱永伟,徐家文.复合平面摆动展成电解加工整体构件异形面的成形分析及应用[J].机械工程学报,2008,44(12):280-286.ZHU Yongwei,XU Jiawen.Shaping law and process study on combined wobbling feeds for electrochemieal contour evolution machining integral component parts[J].Chinese Journal of Mechanical Engineering,2008,44(12):280-286.
[16]朱荻,曲宁松,RAJURKAR K P,等.电极平动式电解孔加工技术研究[J].机械工程学报,2001,37(5):105-109.ZHU Di,QU Ningsun,RAJURKAR K P,et al.Investigation on electrochemical machining with the orbital movement of electrode[J].Chinese Journal of Mechanical Engineering,2001,37(5):105-109.
[17]朱永伟,徐家文,胡平旺.数控展成电解加工整体叶轮的研究与应用[J].航空学报,2001,22(4):376-378.ZHU Yongwei,XU Jiawen,HU Pingwang.Study and application of NC-electrochemical contour evolution machining intergral impeller[J].Acta Aeronautica et Astronautica Sinica,2001,22(4):376-378.
[18]徐庆,朱荻,徐正杨,等.整体叶盘通道电解加工电极多维运动轨迹优化[J].航空学报,2011,32(8):1548-1554.XU Qing,ZHU Di,XU Zhengyang,et al.Optimization of cathode multidimensional movement path in electrochemical machining of blisk tunnels[J].Acta Aeronautica et Astronautica Sinica,2011,32(8):1548-1554.
[19]LAUWERS B,LIU W,Eeraerts W.Influence of the composition of WC-based cermets on manufacturability by wire-EDM[J].Journal of Manufacturing Processes,2006,8(2):83-89.
[20]HAN F,KUNIEDA M,SENDAI T,et al.High precision simulation of WEDM using parametric programming[J].CIRP Annals-Manufacturing Technology,2002,51(1):165-168.
[21]LIAO Y S,YAN M T,CHANG C C.A neural network approach for the on-line estimation of workpiece height in WEDM[J].Journal of Materials Processing Technology,2002,121(2):252-258.
[22]蒲一民.涡轮盘榫槽线切割加工工艺研究[J].航天制造技术,2016,2:37-40,70.PU Yimin.Research on WEDM process of turbine groove[J].Manufacturing Processes Research,2016,2:37-40,70.
[23]赵万生,吴湘,詹涵菁,等.带冠整体式涡轮盘的CAD/CAM[J].推进技术,2003,24(4):380-383.ZHAO Wansheng,WU Xiang,ZHAN Hanjing,et al.CAD CAM of rimed blisks[J].Journal of Propulsion Technology,2003,24(4):380-383.
[24]朱宁,叶军,韩福柱,等.电火花线切割加工技术及其发展动向[J].电加工与模具,2010(S1):53-59.ZHU Ning,YE Jun,HAN Fuzhu.,et al.Development trends of WEDM technology[J].Electromachining&Mould,2010(S1):53-59.
[25]孙殿柱,朱昌志,李延瑞.散乱点云边界特征快速提取算法[J].山东大学学报,2009,39(1):84-86.SUN Dianzhu,ZHU Changzhi,LI Yanrui.An improved extraction of boundary characteristic from scattered data[J].Journal of Shandong University,2009,39(1):84-86.
[2]张学超,史耀耀,任军学,等.闭式叶盘叶身加工切触点规划算法研究与实现[J].航空精密制造技术,2006,42(8):34-37.ZHANG Xuechao,SHI Yaoyao,REN Junxue,et al.Research and implementation of programming algorithm of closed blisk’s blade machining contact points[J].Aviation Precision Manufacturing Technology,2006,42(8):34-37.
[3]任军学,姜振南,姚倡锋,等.开式整体叶盘四坐标高效开槽插铣工艺方法[J].航空学报,2008,29(6):1692-1698.REN Junxue,JIANG Zhengnan,YAO Changfeng,et al.Process for 4-axis high efficiency slot plunge milling of open blisk[J].Acta Aeronautica et Astronautica Sinica,2008,29(6):1692-1698.
[4]单晨伟,任军学,张定华,等.开式整体叶盘四坐标侧铣开槽粗加工轨迹规划[J].中国机械工程,2007,18(16):1917-1920.SHAN Chenwei,REN Junxue,ZHANG Dinghua,et al.4-axis NC side milling roughing path planning for open blisks[J].China Mechanical Engineering,2007,18(16):1917-1920.
[5]任军学,田卫军,田荣鑫,等.开式整体叶盘通道侧铣粗加工技术的研究[J].机械科学与技术,2008,27(10):1220-1224.REN Junxue,TIAN Weijun,TIAN Rongxin,et al.Astudy of the rough milling technique of blisk tunnel[J].Mechanical Science and Technology for Aerospace Engineering,2008,27(10):1220-1224.
[6]DE LACALLE L N L,LAMIKIZ A,SANCHEZ J A,et al.Tool path selection based on the minimum deflection cutting forces in the programming of complex surfaces milling[J].International Journal of Machine Tools and Manufacture,2007,47(2):388-400.
[7]ALTINTAS Y,ENGIN S.Generalized modeling of mechanics and dynamics of milling cutters[J].Annals of the CIRP,2001,50(1):25-30.
[8]ARMAREGO E J A,DESHPANDE N P.Computerized predictive cutting models for force in end-milling including eccentricity effects[J].Annals of the CIRP,1989,38(1):45-49.
[9]王增强,单晨伟,任军学,等.开式整体叶盘四坐标插铣开槽粗加工刀位轨迹规划[J].航空制造技术,2007(2):94-97.WANG Zengqiang,SHAN Chenwei,REN Junxue,et al.Generating 4-axis plunge roughing paths for open blisks[J].Aeronautical Manufacturing Technology,2007,2:94-97.
[10]胡创国,张定华,任军学,等.开式整体叶盘通道插铣粗加技术的研究[J].中国机械工程,2007,18(2):153-155.HU Chuangguo,ZHANG Dinghua,REN Junxue,et al.Research on the plunge milling of blisk tunnel[J].China Mechanical Engineering,2007,18(2):153-155.
[11]李湉,陈五一,陈彩红.整体叶轮插铣粗加工算法[J].计算机集成制造系统,2010,16(8):1696-1701.LI Tian,CHEN Wuyi,CHEN Caihong.Rough machining method for blink plunge milling[J].Computer Integrated Manufacturing Systems,2010,16(8):1696-1701.
[12]董雷,曹利新.通道曲面的柱面逼近方法及其在叶轮插铣中的应用[J].航空学报,2014,35(8):2331-2340.DONG L,CAO L X.Approximation method of tunnel surfaces with general cylindrical surfaces and its application in plunge milling of impellers[J].Acta Aeronautica et Astronautica Sinica,2014,35(8):2331-2340.
[13]BALA M,LAX P,SARMA S,et al.Generating 5-axis NC roughing paths directly from a tessellated representation[J].Computer-aided Design,2000,32(4):261-277.
[14]RISKO D G.DAVYDOV A D.Manufacturing applications and productivity limitations of electrochemical machining[J].Manufacturing Science and Engineering,1993,64:701-711.
[15]朱永伟,徐家文.复合平面摆动展成电解加工整体构件异形面的成形分析及应用[J].机械工程学报,2008,44(12):280-286.ZHU Yongwei,XU Jiawen.Shaping law and process study on combined wobbling feeds for electrochemieal contour evolution machining integral component parts[J].Chinese Journal of Mechanical Engineering,2008,44(12):280-286.
[16]朱荻,曲宁松,RAJURKAR K P,等.电极平动式电解孔加工技术研究[J].机械工程学报,2001,37(5):105-109.ZHU Di,QU Ningsun,RAJURKAR K P,et al.Investigation on electrochemical machining with the orbital movement of electrode[J].Chinese Journal of Mechanical Engineering,2001,37(5):105-109.
[17]朱永伟,徐家文,胡平旺.数控展成电解加工整体叶轮的研究与应用[J].航空学报,2001,22(4):376-378.ZHU Yongwei,XU Jiawen,HU Pingwang.Study and application of NC-electrochemical contour evolution machining intergral impeller[J].Acta Aeronautica et Astronautica Sinica,2001,22(4):376-378.
[18]徐庆,朱荻,徐正杨,等.整体叶盘通道电解加工电极多维运动轨迹优化[J].航空学报,2011,32(8):1548-1554.XU Qing,ZHU Di,XU Zhengyang,et al.Optimization of cathode multidimensional movement path in electrochemical machining of blisk tunnels[J].Acta Aeronautica et Astronautica Sinica,2011,32(8):1548-1554.
[19]LAUWERS B,LIU W,Eeraerts W.Influence of the composition of WC-based cermets on manufacturability by wire-EDM[J].Journal of Manufacturing Processes,2006,8(2):83-89.
[20]HAN F,KUNIEDA M,SENDAI T,et al.High precision simulation of WEDM using parametric programming[J].CIRP Annals-Manufacturing Technology,2002,51(1):165-168.
[21]LIAO Y S,YAN M T,CHANG C C.A neural network approach for the on-line estimation of workpiece height in WEDM[J].Journal of Materials Processing Technology,2002,121(2):252-258.
[22]蒲一民.涡轮盘榫槽线切割加工工艺研究[J].航天制造技术,2016,2:37-40,70.PU Yimin.Research on WEDM process of turbine groove[J].Manufacturing Processes Research,2016,2:37-40,70.
[23]赵万生,吴湘,詹涵菁,等.带冠整体式涡轮盘的CAD/CAM[J].推进技术,2003,24(4):380-383.ZHAO Wansheng,WU Xiang,ZHAN Hanjing,et al.CAD CAM of rimed blisks[J].Journal of Propulsion Technology,2003,24(4):380-383.
[24]朱宁,叶军,韩福柱,等.电火花线切割加工技术及其发展动向[J].电加工与模具,2010(S1):53-59.ZHU Ning,YE Jun,HAN Fuzhu.,et al.Development trends of WEDM technology[J].Electromachining&Mould,2010(S1):53-59.
[25]孙殿柱,朱昌志,李延瑞.散乱点云边界特征快速提取算法[J].山东大学学报,2009,39(1):84-86.SUN Dianzhu,ZHU Changzhi,LI Yanrui.An improved extraction of boundary characteristic from scattered data[J].Journal of Shandong University,2009,39(1):84-86.