难加工材料闭式整体构件精密电火花加工技术研究
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摘要
闭式整体构件因其结构复杂、叶间流道空间弯扭程度大,使得加工可达性极差,且材料一般为难加工的高强度合金,整体制造难度很大。针对这一制造难题,研究了闭式整体构件电火花加工的若干关键技术,如叶间流道加工区域划分、成形电极及其加工运动轨迹设计、工艺基准统一和电参数选择与优化、数控电火花加工过程仿真分析等。在此基础上针对典型闭式整体构件进行了试制加工。试验结果表明,基于所研究的关键技术能够采用数控电火花加工技术精密、可靠地实现闭式整体构件的整体制造。
It is great difficult to manufacture a closed integral component due to its poor processing accessibility caused by complicated structure of air flow channel between two blades, especially the large bending and twisting degree in the channel as well as its component materials of high strength alloy. To solve this problem, several key technologies of electrical discharge machining(EDM) are discussed, such as division of the processing zone among the blades, shaped electrode and its motion trajectory design, process benchmarking unification, process parameters selection and optimization, simulation of EDM process and so on. On top of this, typical closed integral components are studied and manufactured. It is shown from the experimental results the above-mentioned technologies enable numerical control EDM technology to realize precise and reliable manufacture of closed integral components.
It is great difficult to manufacture a closed integral component due to its poor processing accessibility caused by complicated structure of air flow channel between two blades, especially the large bending and twisting degree in the channel as well as its component materials of high strength alloy. To solve this problem, several key technologies of electrical discharge machining(EDM) are discussed, such as division of the processing zone among the blades, shaped electrode and its motion trajectory design, process benchmarking unification, process parameters selection and optimization, simulation of EDM process and so on. On top of this, typical closed integral components are studied and manufactured. It is shown from the experimental results the above-mentioned technologies enable numerical control EDM technology to realize precise and reliable manufacture of closed integral components.
引文
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[15]周旭娇,赵建社,褚辉生,等.整体叶环成组电极电火花高效加工技研究[J].中国机械工程,2016,27(18):2453-2457.ZHOU Xujiao,ZHAO Jianshe,CHUHuisheng,et al.Research on high efficiency EDM process of integral bling with grouped electrodes[J].Chinese Journal of Mechanical Engineering,2016,27(18):2453-2457.
[2]刘辰,徐家文,赵建社,等.三元流闭式叶轮组合电加工技术研究Ⅰ-总体方案设计及关键技术[J].航空学报,2010,31(3):650-654.LIU Chen,XU Jiawen,ZHAO Jianshe,et al.Research on combined electrical machining of 3D-flow closed impellerⅠ-overall scheme design and key technology[J].Acta Aeronautica et Astronautica Sinica,2010,31(3):650-654.
[3]罗姣,李淼泉.高性能整体叶盘制造技术研究进展[J].精密成形工程,2015,7(6):1-7.LUO Jiao,LI Miaoquan.A review on the manufacturing technology of high property blisk[J].Journal of Netshape Forming Engineering,2015,7(6):1-7.
[4]LI Y,ZHAI L J,LIU J Y.Research on electrode design and computer simulation of manufacturing shrouded turbine blisk by EDM[J].Applied Mechanics&Materials,2014,670-671:577-581.
[5]李小丽,马剑雄,李萍,等.3D打印技术及应用趋势[J].自动化仪表,2014,35(1):1-5.LI Xiaoli,MA Jianxiong,LI Ping,et al.3Dprinting technology and its application trend[J].Process Automation Instrumentaion,2014,35(1):1-5.
[6]张磊,云乃彰,郭紫贵.带冠整体叶轮的应用及其加工工艺的研究[J].电加工与模具,2003(2):29-31.ZHANG Lei,YUN Naizhang,GUO Zigui.Application of crown impeller and its machining technology[J].Electromachining&Mould,2003(2):29-31.
[7]王军,赵建社,刘辰,等.闭式整体叶轮叶间流道电解加工阴极设计[J].中国机械工程,2010,21(12):1414-1417.WANG Jun,ZHAO Jianshe,LIU Chen,et al.Cathode design in electrochemical machining of cavities among blades of closed integral impeller[J].Chinese Journal of Mechanical Engineering,2010,21(12):1414-1417.
[8]梁为,康小明,赵万生,等.闭式整体叶盘EBM和EDM组合制造技术[J].电加工与模具,2015(6):62-66.LIANG Wei,KANG Xiaoming,ZHAOWansheng,et al.A combined method of EBMand EDM for shrouded blisk manufacturing[J].Electromachining&Mould,2015(6):62-66.
[9]张志金,孙超,张明岐,等.航空制造领域精密电火花加工技术[J].航空制造技术,2015(23/24):61-63.ZHANG Zhijin,SUN Chao,ZHANGMingqi,et al.Precision EDM technology in aviation manufacturing field[J].Aeronautical Manufacturing Technology,2015(23/24):61-63.
[10]AYESTA I,IZQUIERDO B,SANCHEZ J A.Optimum electrode path generation for EDM manufacturing of aerospace components[J].Robotics and ComputerIntegrated Manufacturing,2016,37:273-281.
[11]赵建社,刘辰,吴锐,等.闭式整体构件组合电加工关键技术研究[J].机械工程学报,2011,47(1):169-175.ZHAO Jian She,LIU Chen,WU Rui,et al.Key technology research of combined electrical machining of closed integral structure[J].Chinese Journal of Mechanical Engineering,2011,47(1):169-175.
[12]赵建社,唐兰剑,郁子欣,等.基于轨迹搜索的闭式三元流通道电火花加工电极设计方法[J].南京航空航天大学学报,2013,45(6):824-828.ZHAO Jianshe,TANG Lanjian,YU Zixin,et al.EDM electrode design based on path searching for closed 3D-flow channel[J].Journal of Nanjing University of Aeronautices&Astronautics,2013,45(6):824-828.
[13]吴彦农,赵建社,唐兰剑,等.闭式复杂流道零件数控电火花加工电极设计[J].中国机械工程,2012,23(20):2430-2433.WU Yannong,ZHAO Jianshe,TANGLanjian,et al.Design method of NC-EDMelectrode for components with closed complex flow channel[J].Chinese Journal of Mechanical Engineering,2012,23(20):2430-2433.
[14]LIU X,KANG X M,XI X C.Electrode feed path planning for multi-axis EDMof integral shrouded impeller[J].International Journal of Advanced Manufacturing Technology,2013,68:1697-1706.
[15]周旭娇,赵建社,褚辉生,等.整体叶环成组电极电火花高效加工技研究[J].中国机械工程,2016,27(18):2453-2457.ZHOU Xujiao,ZHAO Jianshe,CHUHuisheng,et al.Research on high efficiency EDM process of integral bling with grouped electrodes[J].Chinese Journal of Mechanical Engineering,2016,27(18):2453-2457.