整体叶盘多通道电解加工关键技术研究
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摘要
整体叶盘是航空发动机的核心部件之一，其质量决定了发动机的性能和寿命。整体叶盘将叶片和轮毂制作成一个整体，代替通常叶片榫齿与轮毂榫槽再加锁片的联接结构，使零件数量大大减少，整体重量也明显减轻。此外，由于整体叶盘可以消除传统叶片、轮盘结构中气流在榫头与榫槽中逸流所造成的损失，使发动机工作效率提高，从而使整台发动机推重比显著提高。目前整体叶盘正朝着轻量化、整体化方向发展，采用整体叶盘结构是提高发动机推重比和可靠性的关键措施，因此，整体叶盘在先进、高推重比航空发动机及新型大推力火箭发动机中将得到越来越多的应用。
目前整体叶盘的加工方法主要有数控铣削、电火花加工、电解加工等。与传统的加工方法相比，电解加工具有加工效率高、工具无损耗、加工范围广、表面质量好等诸多优点，在整体叶盘的制造中发挥了重要的作用。整体叶盘电解加工分为两个步骤：叶栅通道预加工和叶片形面精密加工。叶栅通道预加工是指在叶盘毛坯圆周方向上加工出若干个通槽并保证不过切，该通槽用于叶片形面精密加工时叶片工具电极能够进入通槽以便完成叶片形面的精密加工。叶栅通道预加工是进行叶盘电解加工必不可少的阶段，也是实现叶盘精加工的基础。文中所做工作为叶栅通道预加工。与国外航空发动机制造大国相比，我国的整体叶盘叶栅通道电解加工水平较为落后，主要是因为缺乏相应的装备和成熟的工艺。我国航空工业的迅速发展对整体叶盘的需求日益迫切，该文正是在这样的背景之下开展整体叶盘通道电解加工的研究工作。
整体叶盘因其结构和叶片形面复杂、加工精度要求高，一直以来都是机械制造领域的难题之一。目前整体叶盘叶栅通道的加工还不能满足航空发动机的需求，如采用传统工艺加工效率低下、刀具易与工件干涉、加工成本较高、留给后续工艺的叶片余量均匀性较差等。为了解决这些难题，作者开展了整体叶盘多通道电解加工的研究工作：
1.提出多工具电极高效电解预加工方法，采用多工具电极同步运动的方式实现整体叶盘多通道电解加工。该方法可以提高整体叶盘通道电解加工的效率，缩短整体叶盘的生产周期。目前该方法已实现3个工具电极同时进行加工，单个通道的平均加工时间仅为采用单个工具电极时的1/3。
2.设计并优化了工具电极和工件的运动轨迹。为了使叶栅通道形面余量分布均匀性良好，提出工具电极在加工过程中转动的方法，设计了工具电极相对于工件的空间运动轨迹，分析了整体叶盘试件通道的精加工余量。并基于电解加工成形规律优化了工具电极的运动轨迹，通过工艺试验验证了轨迹的可行性。
3.设计了整体叶盘多通道电解加工流场。提出采用圆管工具电极进行叶盘通道电解加工的方法，设计了从圆管工具电极一端进液、从管壁上群孔或群缝出液的流动方式。对群孔和群缝的排布进行了优化设计，获得了较为均匀的流场。设计并优化了电解液流动方式，研制了密封均流装置，电解液在加工间隙内的流动得到了控制，电解液充分、连续并充满整个加工间隙，流场的均匀性有了进一步的提高。建立了三维不可压缩模型，对流动方式进行了流场数值仿真。从理论上分析了电解加工的流场特性，设计了与之对应的电解加工夹具。
4.研制了整体叶盘多通道电解加工机床装备。机床系统包括机床本体、电源系统、电解液循环系统、控制系统四个部分。为了提高整体叶盘通道电解加工效率，设计了多工具电极夹持盘，用于控制多个工具电极同步运动，以便同时加工出多个叶栅通道。开发了一套基于工控机的开放式电解加工数控系统，可实现对刀控制、伺服进给、轨迹控制、加工过程监控及短路保护等功能。提高了机床系统的可靠性、稳定性和自动化程度。机床运行平稳，能够满足整体叶盘通道的电解加工需求。
5.设计了整体叶盘叶栅通道电解加工工艺方案。针对进给模式、轨迹修正、流场设计、多工具电极同步加工等环节进行了电解加工试验，检验了上述方案的可行性。试验以高效为基本原则，以加工出通道形面余量小且均匀性良好的整体叶盘为目标。针对某发动机整体叶盘开展了多通道工艺试验研究，加工一个通道平均20min，加工效率显著提高。试验结果表明，加工出的叶盘通道余量小且均匀性良好，能够满足整体叶盘精加工的要求。
Blisk is one of the core components of aircraft engine, and its quality determines the engine’sperformance and life. Blisk combines the blades and the disk together, instead of making the usualblade tenon tooth and disk groove connected by locked chip, which can make the engine’s structuresimple, engine’s weight lighter.Besides, blisk can eliminate the transpiration loss in tenon tooth anddisk groove with traditional spit blade–disk structure, which can improve the engine’s work efficiencyand thrust-weight ratio.
Currently, blisk is becoming more and more lightweightly and integrally. Adopting blisk is keymeasurement of making engine’s reliability better and thrust-weight ratio higher, so blisk is morepopularly used in advanced air engines and new rocket with high thrust-weight ratio. Blisk machiningprocess includes computer numerical control(CNC), electric discharge machining andElectrochemical machining(ECM). Contrast to traditional process, ECM has many advantages such asno electrode loss, high efficiency, low production cost, and no restriction from mechanical propertiesof metals, etc.These advantages can satisfy the need of machining of blisk channel, so ECM plays animportant role in blisk machining. ECM of blisk is divided into two steps: channel rough machiningand blade surface precise machining. Blisk channel rough machining is indispensable process of bliskECM and is the foundation of blisk precise machining. Compared with foreign aircraft enginemanufacturing country, ours blisk channel machining is lagging behind, mainly as lacking ofcorresponding equipment and matured process.With the rapid development of ours air industry, blisksare required urgently on which this paper expounds the research on ECM of blisk channel.
Blisk machining is all the time a difficult problem of machinofacture as blisks have complexstructure and blade profile as well as high machining precision. Currently, aero engine’s demand can’tbe satisfied with traditional processes including low machining efficiency in blisk channel machining,tool’s interference with workpiece, high processing costs, and low uniformity distribution offollowing process margin. For solving these problems, this paper carried out interrelated research inseveral aspects:
1.A method of multi-cathodes being used in machining is raised to achieve ECM of bliskchannels with multi-cathodes simultaneously feeding. The method can improve the efficiency of ECMof blisk channel and decrease the production cycle. Currently，three cathodes can be simultaneouslyused in machining，with which the channel processing time is redused by2/3.
2.The movement path of electrode and workpiece is designed and optimized. For improve theuniformity of channel surface margin, the method of cathode revolving in the process is raised，thespace movement path of tool cathode relative to workpiece is designed and the finishing margin ofbilsk channel is analyzed. The movement path of cathodes is optimized based on ECM formingdiscipline.Relevant experiment reveals that the path is reasonable.
3.The flow field of ECM of blisk multi-channels is designed. Tube cathodes are proposed to beused in ECM of blisk channels.The flow mode that electrolyte flows into one end of the cathode andout of the outflux on cathode pipe wall is designed.The distribution of groups of holes or seams isoptimized to achieve uniform flow field. Flow mode is designed and optimized，gland even flow bushin which the electrolyte flow path can be controlled is developed, for making the uniformity of flowfield further improved. Incompressible three-dimensional model is established and the flow fieldnumerical simulation is carried out with Fluent. The flow characteristics of ECM is analyzedtheoretically and corresponding clamp is designed.
4.An ECM machine equipment for blisk channels is developed. The machine system includesfour parts, such as machine itself, power system, electrolyte circulation system and control system.For improve the efficiency of ECM of blisk channel, multi-cathode clamping plate is designed forcontrolling multiple cathodes simultaneously moving to achieve ECM of blisk channels withmulti-cathodes.A CNC system of ECM of blisk channels is developed. The system has many powerfulfunctions, such as tool setting control, servo feed, process monitoring and short circuit protection,which make the ECM machine more reliability, stability and automatic. The machine runs steadilyand can meet the need of ECM of blisk channels.
5.The process program of blisk multi-channels ECM is designed. In connection with many linksuch as feed mode, path correction, flow field design, multi-cathodes being used in process, ECMexperiments are carried out for checking the feasibility of these plans. The experiment is based on theprinciple of high efficiency, for machining blisk with small margin and well uniformity. In connectionwith a blisk of some air engine, experiments are carried out. The result reveals that machining onechannel only takes20minutes, which increases the efficiency remarkably. The experiment result thatmachined blisk channel can meet the need of the finishing process.
目前整体叶盘的加工方法主要有数控铣削、电火花加工、电解加工等。与传统的加工方法相比，电解加工具有加工效率高、工具无损耗、加工范围广、表面质量好等诸多优点，在整体叶盘的制造中发挥了重要的作用。整体叶盘电解加工分为两个步骤：叶栅通道预加工和叶片形面精密加工。叶栅通道预加工是指在叶盘毛坯圆周方向上加工出若干个通槽并保证不过切，该通槽用于叶片形面精密加工时叶片工具电极能够进入通槽以便完成叶片形面的精密加工。叶栅通道预加工是进行叶盘电解加工必不可少的阶段，也是实现叶盘精加工的基础。文中所做工作为叶栅通道预加工。与国外航空发动机制造大国相比，我国的整体叶盘叶栅通道电解加工水平较为落后，主要是因为缺乏相应的装备和成熟的工艺。我国航空工业的迅速发展对整体叶盘的需求日益迫切，该文正是在这样的背景之下开展整体叶盘通道电解加工的研究工作。
整体叶盘因其结构和叶片形面复杂、加工精度要求高，一直以来都是机械制造领域的难题之一。目前整体叶盘叶栅通道的加工还不能满足航空发动机的需求，如采用传统工艺加工效率低下、刀具易与工件干涉、加工成本较高、留给后续工艺的叶片余量均匀性较差等。为了解决这些难题，作者开展了整体叶盘多通道电解加工的研究工作：
1.提出多工具电极高效电解预加工方法，采用多工具电极同步运动的方式实现整体叶盘多通道电解加工。该方法可以提高整体叶盘通道电解加工的效率，缩短整体叶盘的生产周期。目前该方法已实现3个工具电极同时进行加工，单个通道的平均加工时间仅为采用单个工具电极时的1/3。
2.设计并优化了工具电极和工件的运动轨迹。为了使叶栅通道形面余量分布均匀性良好，提出工具电极在加工过程中转动的方法，设计了工具电极相对于工件的空间运动轨迹，分析了整体叶盘试件通道的精加工余量。并基于电解加工成形规律优化了工具电极的运动轨迹，通过工艺试验验证了轨迹的可行性。
3.设计了整体叶盘多通道电解加工流场。提出采用圆管工具电极进行叶盘通道电解加工的方法，设计了从圆管工具电极一端进液、从管壁上群孔或群缝出液的流动方式。对群孔和群缝的排布进行了优化设计，获得了较为均匀的流场。设计并优化了电解液流动方式，研制了密封均流装置，电解液在加工间隙内的流动得到了控制，电解液充分、连续并充满整个加工间隙，流场的均匀性有了进一步的提高。建立了三维不可压缩模型，对流动方式进行了流场数值仿真。从理论上分析了电解加工的流场特性，设计了与之对应的电解加工夹具。
4.研制了整体叶盘多通道电解加工机床装备。机床系统包括机床本体、电源系统、电解液循环系统、控制系统四个部分。为了提高整体叶盘通道电解加工效率，设计了多工具电极夹持盘，用于控制多个工具电极同步运动，以便同时加工出多个叶栅通道。开发了一套基于工控机的开放式电解加工数控系统，可实现对刀控制、伺服进给、轨迹控制、加工过程监控及短路保护等功能。提高了机床系统的可靠性、稳定性和自动化程度。机床运行平稳，能够满足整体叶盘通道的电解加工需求。
5.设计了整体叶盘叶栅通道电解加工工艺方案。针对进给模式、轨迹修正、流场设计、多工具电极同步加工等环节进行了电解加工试验，检验了上述方案的可行性。试验以高效为基本原则，以加工出通道形面余量小且均匀性良好的整体叶盘为目标。针对某发动机整体叶盘开展了多通道工艺试验研究，加工一个通道平均20min，加工效率显著提高。试验结果表明，加工出的叶盘通道余量小且均匀性良好，能够满足整体叶盘精加工的要求。
Blisk is one of the core components of aircraft engine, and its quality determines the engine’sperformance and life. Blisk combines the blades and the disk together, instead of making the usualblade tenon tooth and disk groove connected by locked chip, which can make the engine’s structuresimple, engine’s weight lighter.Besides, blisk can eliminate the transpiration loss in tenon tooth anddisk groove with traditional spit blade–disk structure, which can improve the engine’s work efficiencyand thrust-weight ratio.
Currently, blisk is becoming more and more lightweightly and integrally. Adopting blisk is keymeasurement of making engine’s reliability better and thrust-weight ratio higher, so blisk is morepopularly used in advanced air engines and new rocket with high thrust-weight ratio. Blisk machiningprocess includes computer numerical control(CNC), electric discharge machining andElectrochemical machining(ECM). Contrast to traditional process, ECM has many advantages such asno electrode loss, high efficiency, low production cost, and no restriction from mechanical propertiesof metals, etc.These advantages can satisfy the need of machining of blisk channel, so ECM plays animportant role in blisk machining. ECM of blisk is divided into two steps: channel rough machiningand blade surface precise machining. Blisk channel rough machining is indispensable process of bliskECM and is the foundation of blisk precise machining. Compared with foreign aircraft enginemanufacturing country, ours blisk channel machining is lagging behind, mainly as lacking ofcorresponding equipment and matured process.With the rapid development of ours air industry, blisksare required urgently on which this paper expounds the research on ECM of blisk channel.
Blisk machining is all the time a difficult problem of machinofacture as blisks have complexstructure and blade profile as well as high machining precision. Currently, aero engine’s demand can’tbe satisfied with traditional processes including low machining efficiency in blisk channel machining,tool’s interference with workpiece, high processing costs, and low uniformity distribution offollowing process margin. For solving these problems, this paper carried out interrelated research inseveral aspects:
1.A method of multi-cathodes being used in machining is raised to achieve ECM of bliskchannels with multi-cathodes simultaneously feeding. The method can improve the efficiency of ECMof blisk channel and decrease the production cycle. Currently，three cathodes can be simultaneouslyused in machining，with which the channel processing time is redused by2/3.
2.The movement path of electrode and workpiece is designed and optimized. For improve theuniformity of channel surface margin, the method of cathode revolving in the process is raised，thespace movement path of tool cathode relative to workpiece is designed and the finishing margin ofbilsk channel is analyzed. The movement path of cathodes is optimized based on ECM formingdiscipline.Relevant experiment reveals that the path is reasonable.
3.The flow field of ECM of blisk multi-channels is designed. Tube cathodes are proposed to beused in ECM of blisk channels.The flow mode that electrolyte flows into one end of the cathode andout of the outflux on cathode pipe wall is designed.The distribution of groups of holes or seams isoptimized to achieve uniform flow field. Flow mode is designed and optimized，gland even flow bushin which the electrolyte flow path can be controlled is developed, for making the uniformity of flowfield further improved. Incompressible three-dimensional model is established and the flow fieldnumerical simulation is carried out with Fluent. The flow characteristics of ECM is analyzedtheoretically and corresponding clamp is designed.
4.An ECM machine equipment for blisk channels is developed. The machine system includesfour parts, such as machine itself, power system, electrolyte circulation system and control system.For improve the efficiency of ECM of blisk channel, multi-cathode clamping plate is designed forcontrolling multiple cathodes simultaneously moving to achieve ECM of blisk channels withmulti-cathodes.A CNC system of ECM of blisk channels is developed. The system has many powerfulfunctions, such as tool setting control, servo feed, process monitoring and short circuit protection,which make the ECM machine more reliability, stability and automatic. The machine runs steadilyand can meet the need of ECM of blisk channels.
5.The process program of blisk multi-channels ECM is designed. In connection with many linksuch as feed mode, path correction, flow field design, multi-cathodes being used in process, ECMexperiments are carried out for checking the feasibility of these plans. The experiment is based on theprinciple of high efficiency, for machining blisk with small margin and well uniformity. In connectionwith a blisk of some air engine, experiments are carried out. The result reveals that machining onechannel only takes20minutes, which increases the efficiency remarkably. The experiment result thatmachined blisk channel can meet the need of the finishing process.
引文
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