航发涡轮叶片气膜孔的磨削加工实验
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摘要
针对目前航空发动机涡轮叶片气膜孔加工精度低和重熔层难去除的问题,提出了"电火花打孔、磨削扩孔"的新型气膜孔加工工艺,研制出小孔磨削专用微细CBN砂轮并对电火花气膜孔进行了磨削工艺实验。实验结果表明:经磨削加工后气膜孔圆度降低50.9%,孔径尺寸标准差降低90.7%,表面粗糙度降低65.9%,重熔层被全部去除,证明了航发涡轮叶片气膜孔磨削加工的可行性。
For the problem that the machining precision of film cooling hole of aero-engine turbine blade is low and the recast layer is difficult to be removed. A new film cooling hole process which is mainly based on the thought of using EDM to drill and using grinding to expand is proposed. Grinding experiment was carried out on the film cooling hole machined by EDM using the special fine CBN grinding wheel. The result shows that after the grinding process,the roundness of the film hole is reduced by 50.9%, the standard deviation of the hole size is reduced by 90.7%, the surface roughness is reduced by 65.9%, and the recast layer is completely removed, proving the feasibility of the grinding approach of film cooling hole of aero-engine turbine blade.
For the problem that the machining precision of film cooling hole of aero-engine turbine blade is low and the recast layer is difficult to be removed. A new film cooling hole process which is mainly based on the thought of using EDM to drill and using grinding to expand is proposed. Grinding experiment was carried out on the film cooling hole machined by EDM using the special fine CBN grinding wheel. The result shows that after the grinding process,the roundness of the film hole is reduced by 50.9%, the standard deviation of the hole size is reduced by 90.7%, the surface roughness is reduced by 65.9%, and the recast layer is completely removed, proving the feasibility of the grinding approach of film cooling hole of aero-engine turbine blade.
引文
[1]倪萌,朱惠人,裘云,等.航空发动机涡轮叶片冷却技术综述[J].燃气轮机技术,2005, 18(4):25-33.
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[5]何英,朱红钢,韩野.航空发动机小孔特种加工技术[J].航空制造技术,2011(4):56-60.
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[7]崔智勇,刘遵友,王轶,等.叶片气膜孔加工再铸层控制[J].机械工程师,2013(11):208-209.
[8] KONONENKO T V, FREITAG C, SOVYK D N, et al.Influence of pulse repetition rate on percussion drilling of Tibased alloy by picosecond laser pulses[J]. Optics and Lasers in Engineering, 2018(103):65-70.
[9]彭国平,彭秀云.发动机涡轮导向叶片气膜孔的加工工艺[J].航天制造技术,2008(6):26-29.
[10] ZHANG Y, XU Z Y, ZHU Y, et al. Machining of a film-cooling hole in a single-crystal superalloy by high-speed electrochemical discharge drilling[J]. Chinese Journal of Aeronautics, 2016, 29(2):560-570.
[11] LIANG J W, Al X, WEN Z X, et al. Experimental in-vestigation on low cycle fatigue of DZ125 with film cooling holes in different processes of laser drilling[J]. Engineering Failure Analysis, 2016(59):326-333.
[12] IZQUIERDO B, PLAZA S, SANCHEZ J A, et al. Numerical prediction of heat affected layer in the EDM of aeronautical alloys[J]. Applied Surface Science, 2012(259):780-790.
[13] MUHAMMAD A, MIZRA J, JUNAID A A, et al. Parametric analysis of recast layer formation in wire-cut EDM of HSLA steel[J]. International Journal of Advanced Manufacturing Technology, 2016(87):713-722.
[14] WANG C C, ZHOU H M, YANG L D, et al. Recast layer removal after electrical discharge machining via Taguchi analysis:A feasibility study[J]. Journal of Materials Processing Technology, 2009(209):4134-4140.
[15] WEN Z, PEI H, ZHANG C, et al. Analysis of surface quality of multi-film cooling holes in nickel-based single crystal superalloy[J]. Metal Science Journal, 2016, 32(18):1845-1854.
[2] BOGARD D G, THOLE K A. Gas Turbine Film Cooling[J]. Journal of Propulsion and Power, 2006, 22(2):249-270.
[3]王富强,张志强.涡轮冷却叶片气膜孔加工方法研究[C].第16届全国特种加工学术会议,苏州:中国机械工程学会特种加工分会,2015:405-408.
[4]陈贵林,柳万珠.航空发动机先进制造技术[M].西安:西北工业大学出版社,2015:97-100.
[5]何英,朱红钢,韩野.航空发动机小孔特种加工技术[J].航空制造技术,2011(4):56-60.
[6]齐歆霞,朱海南.航空发动机叶片气膜孔加工工艺分析[C].第14届全国特种加工学术会议,苏州:中国机械工程学会特种加工分会,2011:160-163.
[7]崔智勇,刘遵友,王轶,等.叶片气膜孔加工再铸层控制[J].机械工程师,2013(11):208-209.
[8] KONONENKO T V, FREITAG C, SOVYK D N, et al.Influence of pulse repetition rate on percussion drilling of Tibased alloy by picosecond laser pulses[J]. Optics and Lasers in Engineering, 2018(103):65-70.
[9]彭国平,彭秀云.发动机涡轮导向叶片气膜孔的加工工艺[J].航天制造技术,2008(6):26-29.
[10] ZHANG Y, XU Z Y, ZHU Y, et al. Machining of a film-cooling hole in a single-crystal superalloy by high-speed electrochemical discharge drilling[J]. Chinese Journal of Aeronautics, 2016, 29(2):560-570.
[11] LIANG J W, Al X, WEN Z X, et al. Experimental in-vestigation on low cycle fatigue of DZ125 with film cooling holes in different processes of laser drilling[J]. Engineering Failure Analysis, 2016(59):326-333.
[12] IZQUIERDO B, PLAZA S, SANCHEZ J A, et al. Numerical prediction of heat affected layer in the EDM of aeronautical alloys[J]. Applied Surface Science, 2012(259):780-790.
[13] MUHAMMAD A, MIZRA J, JUNAID A A, et al. Parametric analysis of recast layer formation in wire-cut EDM of HSLA steel[J]. International Journal of Advanced Manufacturing Technology, 2016(87):713-722.
[14] WANG C C, ZHOU H M, YANG L D, et al. Recast layer removal after electrical discharge machining via Taguchi analysis:A feasibility study[J]. Journal of Materials Processing Technology, 2009(209):4134-4140.
[15] WEN Z, PEI H, ZHANG C, et al. Analysis of surface quality of multi-film cooling holes in nickel-based single crystal superalloy[J]. Metal Science Journal, 2016, 32(18):1845-1854.