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CN105057969B - Repairing method of solid impeller disc based on MICROBEAM PLASMA WELDING and electric spark finishing - Google Patents

Repairing method of solid impeller disc based on MICROBEAM PLASMA WELDING and electric spark finishing Download PDF

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Publication number
CN105057969B
CN105057969B CN201510289304.9A CN201510289304A CN105057969B CN 105057969 B CN105057969 B CN 105057969B CN 201510289304 A CN201510289304 A CN 201510289304A CN 105057969 B CN105057969 B CN 105057969B
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blisk
blade
welding
electric spark
finishing
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CN105057969A (en
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王伊卿
陈剑
卢秉恒
曾泽文
王彬
刘红忠
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Xian Jiaotong University
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00Restoring or reconditioning objects
    • B23P6/002Repairing turbine components, e.g. moving or stationary blades, rotors

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

本发明公开基于微束等离子焊接和电火花精整的整体叶盘修复方法,利用微束等离子焊接的方法在叶片顶端、叶片边沿熔覆堆焊金属,完成叶片顶端、叶片边沿磨损或损伤部位的熔覆堆焊;对叶片顶端、叶片边沿、叶片顶端熔覆堆焊部位进行电火花精整加工,最后利用湿吹沙工艺去除掉叶片电火花加工中出现的熔凝层,并对叶片进行抛光处理;将型面已经修复好的整体叶盘装在外圆磨床上,进行整体叶盘外圆高速磨削并达到叶片的长度尺寸,完成整体叶盘叶片顶部、叶片边沿磨损或损伤的修复工作;本发明在叶片型面的基础上快速、精确地修复叶顶和叶片边沿的磨损或损伤,完成叶片的再制造,恢复叶片的使用性能。

The invention discloses a method for repairing an integral blade disc based on micro-beam plasma welding and electric spark finishing. The micro-beam plasma welding method is used to clad and surfacing metal on the top and edge of the blade to complete the repair of the worn or damaged parts of the top and edge of the blade. Cladding and surfacing; EDM finishing is performed on the top of the blade, the edge of the blade, and the cladding and surfacing parts of the blade, and finally the fused layer that appears in the EDM of the blade is removed by wet sand blowing technology, and the blade is polished Processing: install the blisk whose profile has been repaired on the cylindrical grinding machine, perform high-speed grinding on the outer circle of the blisk to reach the length of the blade, and complete the repair of the top of the blisk and the edge of the blade for wear or damage; The invention quickly and accurately repairs the wear or damage of the blade top and the edge of the blade on the basis of the profile of the blade, completes the remanufacturing of the blade, and restores the service performance of the blade.

Description

基于微束等离子焊接和电火花精整的整体叶盘修复方法Blisk Repair Method Based on Microbeam Plasma Welding and EDM

【技术领域】【Technical field】

本发明属于叶片修复技术领域,涉及基于微束等离子焊接和电火花精整的整体叶盘修复方法。The invention belongs to the technical field of blade repair, and relates to a method for repairing an integral blade disk based on micro-beam plasma welding and electric spark finishing.

【背景技术】【Background technique】

整体叶盘的结构非常复杂,通道开敞性差,叶片薄、弯扭大、易变形,同时航空发动机和燃气轮机整体叶盘制造材料主要采用钛合金、高温合金等高性能金属材料和钛基、钛铝化合物等先进复合材料,不仅增加了制造难度,也对叶盘的维修提出了严峻的挑战。目前国内整体叶盘修复主要靠人工焊接修复和手工打磨,修复精度低,修复时间长,增加了整体叶盘的维护成本。The structure of the overall blisk is very complex, the channel opening is poor, the blade is thin, the bending is large, and it is easy to deform. Advanced composite materials such as aluminum compounds not only increase the difficulty of manufacturing, but also pose serious challenges to the maintenance of blisks. At present, the overall blisk repair in China mainly relies on manual welding and manual grinding, which has low repair accuracy and long repair time, which increases the maintenance cost of the overall blisk.

整体叶盘一般工作在高压、高速气流、高温、气流交变等复杂工况,叶片顶端、叶片边沿容易发生磨损、变形及其它损伤,其中叶片顶端、叶片边沿的磨损是叶片的主要破坏方式,不同于热腐蚀损伤或外物冲击损伤,叶片基体大都完好无损。航空发动机和燃气轮机的整体叶盘在使用指定时间后要进行检修,检修的主要内容就是叶片的检修,由于叶片数量大,且制造工艺复杂,价格昂贵,修复叶片成本远远低于更换新成本,其修复成本仅为叶片制造成本的5%,因此如何在短时间内修复整体叶盘上已经磨损或损伤的叶片,恢复其使用性能已成为整体叶盘设计、制造及使用的一个关键问题。The overall blisk generally works in complex working conditions such as high pressure, high-speed airflow, high temperature, and alternating airflow. The tip and edge of the blade are prone to wear, deformation, and other damage. Among them, the wear of the tip and edge of the blade is the main damage mode of the blade. Unlike thermal corrosion damage or foreign object impact damage, the blade matrix is mostly intact. The overall blisks of aero-engines and gas turbines need to be overhauled after a specified period of use. The main content of the overhaul is the overhaul of the blades. Due to the large number of blades, the complicated manufacturing process, and the high price, the cost of repairing blades is far lower than the cost of replacing new ones. Its repair cost is only 5% of the blade manufacturing cost, so how to repair the worn or damaged blades on the blisk in a short time and restore its performance has become a key issue in the design, manufacture and use of the blisk.

【发明内容】【Content of invention】

针对上述现有技术存在的缺陷或不足,本发明的目的在于,提供一种基于微束等离子焊接和电火花精整的整体叶盘修复方法;该方法可以在较短时间内完成叶片的修复,恢复叶片的使用性能,另外本发明有利于提高整体叶盘修复加工的自动化程度,提高整体叶盘修复加工效率,克服手工打磨叶片带来的叶片型面精度、叶片表面粗糙度不易控制等问题,实现整体叶盘叶片修复过程的数字化控制。In view of the defects or deficiencies in the above-mentioned prior art, the purpose of the present invention is to provide a method for repairing the overall blisk based on micro-beam plasma welding and electric spark finishing; this method can complete the repair of the blade in a relatively short period of time, Restoring the service performance of the blade, and in addition, the present invention is conducive to improving the automation degree of the overall blisk repair process, improving the efficiency of the overall blisk repair process, and overcoming the problems of blade surface accuracy and blade surface roughness caused by manual grinding of blades, etc. Realize the digital control of the overall blisk blade repair process.

为了实现上述目的,本发明采用如下技术方案:In order to achieve the above object, the present invention adopts the following technical solutions:

基于微束等离子焊接和电火花精整的整体叶盘修复方法,包括以下步骤:The overall blisk repair method based on micro-beam plasma welding and electric spark finishing includes the following steps:

1)把整体叶盘安装在变位机上,选取一个待修复叶片为基准,调整变位机姿态,使该叶片端面正对于线激光扫描器下方;1) Install the blisk on the positioner, select a blade to be repaired as a reference, and adjust the attitude of the positioner so that the end face of the blade is directly below the line laser scanner;

2)调整线激光扫描器,使其沿平行于该目标叶片磨损面方向移动得到整体叶盘叶片磨损部位轮廓的三维离散点,通过分割算法得到整体叶盘叶片磨损部位的焊接轨迹;2) Adjust the line laser scanner so that it moves in a direction parallel to the worn surface of the target blade to obtain the three-dimensional discrete points of the contour of the worn part of the blade of the overall blisk, and obtain the welding trajectory of the worn part of the blade of the blisk through a segmentation algorithm;

3)将步骤2)中扫描得到的焊接轨迹通过离线编程产生控制程序,并通过离线编程产生的程序控制控制焊接机器人和变位机同步协调运动,实现目标叶片磨损部位微束等离子熔覆堆焊;3) The welding trajectory scanned in step 2) is used to generate a control program through offline programming, and the program generated by offline programming is used to control the synchronous and coordinated movement of the welding robot and the positioner to achieve micro-beam plasma cladding surfacing on the worn part of the target blade ;

4)调整变位机姿态,使目标叶片的下一个磨损部位正对于线激光扫描器下方;重复步骤2)和步骤3),直至微束等离子熔覆堆焊完目标叶片的所有磨损部位;4) Adjust the posture of the positioner so that the next worn part of the target blade is directly below the line laser scanner; repeat steps 2) and 3) until all worn parts of the target blade are finished by micro-beam plasma cladding and surfacing;

5)变位机旋转一定角度,该角度为叶片在叶轮上的分布角度,以下一个磨损叶片为微束等离子熔覆堆焊目标,重复步骤2)—4),直到完成整体叶盘所有叶片磨损部位的微束等离子熔覆堆焊;5) The positioner rotates at a certain angle, which is the distribution angle of the blades on the impeller, and the next worn blade is the microbeam plasma cladding surfacing welding target, repeat steps 2)-4) until all blades of the overall blisk are worn Micro-beam plasma cladding surfacing welding;

6)将步骤5)得到的微束等离子熔覆堆焊后的整体叶盘放入到热等静压机中进行热等静压处理;6) putting the blisk obtained in step 5) into a hot isostatic pressing machine for hot isostatic pressing;

7)将经步骤6)得到的热等静压处理后整体叶盘装夹到三坐标测量机中,测量热等静压处理后的整体叶盘,完成叶盘、叶片表面完整的点云数据采集,建立热等静压处理后整体叶盘的实际三维模型;7) Clamp the blisk after the hot isostatic pressing process obtained in step 6 into a three-coordinate measuring machine, measure the blisk after the hot isostatic pressing, and complete the complete point cloud data of the blisk and the blade surface Acquisition and establishment of the actual 3D model of the blisk after hot isostatic pressing;

8)通过对比热等静压处理后整体叶盘的实际三维模型与整体叶盘的设计三维模型,得到热等静压处理后整体叶盘的实际三维模型相对于整体叶盘的设计三维模型的精度误差及变形量;8) By comparing the actual 3D model of the blisk after HIP treatment with the design 3D model of the blisk, the difference between the actual 3D model of the blisk after HIP treatment and the design 3D model of the blisk is obtained. Accuracy error and deformation;

9)根据步骤8)得到的精度误差及变形量,确定电火花加工余量;9) According to the precision error and the amount of deformation obtained in step 8), determine the EDM allowance;

10)根据叶盘叶片设计三维模型,获取叶片仿形阴极,设计电火花加工电极;10) Design the three-dimensional model according to the blisk blade, obtain the profiling cathode of the blade, and design the EDM electrode;

11)把经过步骤6)处理得到的热等静压处理后整体叶盘装夹到五轴电火花加工机床的工作台上,根据步骤9)得到的加工余量和步骤10)设计的电火花加工电极对热等静压处理后的整体叶盘进行电火花加工,得到修复后整体叶盘;11) Clamp the blisk after the hot isostatic pressing treatment obtained in step 6) onto the workbench of the five-axis EDM machine tool, and according to the machining allowance obtained in step 9) and the EDM designed in step 10) The machining electrode conducts electric discharge machining on the blisk after hot isostatic pressing to obtain the blisk after repair;

12)将经步骤11)得到的修复后整体叶盘装夹到三坐标测量机中,测量修复后整体叶盘,建立修复后整体叶盘的实际三维模型;然后将修复后整体叶盘的实际三维模型与设计三维模型进行对比,得到修复后整体叶盘的最终精度误差及最终变形量;12) Clamp the blisk after repair obtained in step 11) into a three-coordinate measuring machine, measure the blisk after repair, and establish the actual three-dimensional model of the blisk after repair; The 3D model is compared with the design 3D model to obtain the final accuracy error and final deformation of the whole blisk after repair;

13)根据修复后整体叶盘的最终精度误差及最终变形量判断整体叶盘是否合格,当合格时,则采用湿吹沙、振动光饰和喷丸工艺对修复后的整体叶盘进行表面处理,然后再对修复后整体叶盘的叶片顶端进行外圆磨削,达到叶片的长度尺寸,得到修复的整体叶盘。13) According to the final accuracy error and final deformation of the whole blisk after repair, it is judged whether the whole blisk is qualified. If it is qualified, the surface treatment of the whole blisk after repair is carried out by wet sand blowing, vibrating finishing and shot peening. , and then perform cylindrical grinding on the top of the blade of the repaired blisk to reach the length of the blade, and obtain the repaired blisk.

本发明进一步的改进在于:还包括以下步骤:The further improvement of the present invention is: also comprise the following steps:

14)对步骤13)修复的整个叶盘叶片进行无损探伤后,最后进行大功率试车。14) After performing non-destructive testing on the entire blisk blade repaired in step 13), a high-power test run is finally carried out.

本发明进一步的改进在于:步骤2)具体为:线激光扫描器沿平行于叶片顶端面方向以速度V移动,且由式V=Df确定;其中:V为线激光扫描器扫描速度,单位为mm/s;D为线激光扫描器扫描精度,单位为mm,和获取叶片顶端三维离散点轮廓的数据精度有关;f为线激光扫描器扫描频率,单位为Hz;通过线激光扫描器获取整体叶盘叶片顶端两条轮廓的三维离散点,通过(xi,yi,zi)={(x1i+x2i)/(n+1),(y1i+y2i)/(n+1),(z1i+z2i)/(n+1)},得到整体叶盘叶片顶端磨损焊接修复轨迹,其中(xi,yi,zi)为焊接修复轨迹离散点,(x1i,y1i,z1i)和(x2i,y2i,z2i)为整体叶盘叶片顶端两条轮廓的三维离散点,n为焊接修复的焊道数。The further improvement of the present invention is: step 2) is specifically: the line laser scanner moves with speed V along the direction parallel to the top surface of the blade, and is determined by the formula V=Df; wherein: V is the scanning speed of the line laser scanner, and the unit is mm/s; D is the scanning accuracy of the line laser scanner, the unit is mm, which is related to the data accuracy of obtaining the three-dimensional discrete point profile of the blade tip; f is the scanning frequency of the line laser scanner, the unit is Hz; The three-dimensional discrete points of the two contours at the top of the leaf disk blade, through ( xi ,y i , zi )={(x 1i +x 2i )/(n+1), (y 1i +y 2i )/(n+ 1), (z 1i +z 2i )/(n+1)}, to obtain the welding repair trajectory of the blade tip wear of the blisk, where (x i , y i , z i ) are the discrete points of the welding repair trajectory, (x 1i ,y 1i ,z 1i ) and (x 2i ,y 2i ,z 2i ) are the three-dimensional discrete points of the two contours at the top of the blisk blade, and n is the number of weld passes for welding repair.

本发明进一步的改进在于:步骤3)中微束等离子熔覆堆焊参数具体为:压缩喷嘴直径:0.6~1.2mm;焊接速度:0.25~0.65cm·s-1;焊接电流:5~16A;焊接电压:22~35V;氩气保护气体流量为24~36L·h-1;送粉速率为3-10g·s-1The further improvement of the present invention lies in: the parameters of the micro-beam plasma cladding and surfacing welding in step 3) are specifically: compression nozzle diameter: 0.6-1.2mm; welding speed: 0.25-0.65cm·s -1 ; welding current: 5-16A; Welding voltage: 22~35V; flow rate of argon shielding gas: 24~36L·h -1 ; powder feeding rate: 3-10g·s -1 .

本发明进一步的改进在于:步骤6)具体为:将焊接修复得到的整体叶盘坯体放入到热等静压机中,加热到940℃,并加压到200MPa,保温恒压1h;然后冷却至650℃,并减压至110MPa,再保温恒压2-4h;最后再冷却至500℃,并减压至大气压,然后再随炉冷却至室温。The further improvement of the present invention lies in: step 6) is specifically: put the blisk green body obtained by welding and repairing into a hot isostatic press, heat it to 940° C., pressurize it to 200 MPa, and keep it under constant pressure for 1 hour; then Cool to 650°C, and decompress to 110MPa, then keep the temperature at constant pressure for 2-4h; finally cool to 500°C, and depressurize to atmospheric pressure, and then cool to room temperature with the furnace.

本发明进一步的改进在于:步骤11)的具体操作为:将整体叶盘坯体水平安装在五轴联动电火花机床的变位机工作台上,采用煤油工作液、紫铜材质的球状或圆柱工具电极,设置整体叶盘的极性为正极,选用等能量方波的电源模式,设置电火花铣削机床参数后根据电火花加工余量分别对整体叶盘叶片顶端和叶片边沿进行电火花精整加工;电火花铣削机床参数为:脉冲宽度为5-30μs,脉冲间隙为15-40μs,电流密度为17.52-84.39A/cm2,间隙电压为35-70V。The further improvement of the present invention lies in: the specific operation of step 11) is: horizontally install the blisk body on the positioner workbench of the five-axis linkage EDM machine tool, and use kerosene working fluid and a spherical or cylindrical tool made of copper Electrode, set the polarity of the overall blisk to positive, select the power supply mode of equal energy square wave, set the parameters of the EDM machine tool, and then perform EDM finishing on the top and edge of the overall blisk according to the EDM allowance ; The parameters of the EDM machine tool are: pulse width 5-30μs, pulse gap 15-40μs, current density 17.52-84.39A/cm 2 , gap voltage 35-70V.

本发明进一步的改进在于:步骤13)中对整体叶盘样品进行磨削的具体过程为:将整体叶盘样品安装到外圆磨床上,通过外圆磨床对整体叶盘样品上叶片的端面进行磨削,磨削过程中,整体叶盘样品的转速为6000r/min,砂轮线速度为120m/s,纵向进给速度为0.01mm/min,外圆磨床采用水基冷却方式注水,其中,水的流量为90L/min、扬程为5.5m。The further improvement of the present invention is: the specific process of grinding the blisk sample in step 13) is: the blisk sample is installed on the cylindrical grinder, and the end surface of the blade on the blisk sample is ground by the cylindrical grinder. Grinding. During the grinding process, the rotation speed of the blisk sample is 6000r/min, the linear speed of the grinding wheel is 120m/s, and the longitudinal feed speed is 0.01mm/min. The flow rate is 90L/min and the head is 5.5m.

本发明的目的是提供一种基于微束等离子焊接和电火花精整的整体叶盘叶片修复技术,在叶片型面的基础上快速、精确地修复叶顶和叶片边沿的磨损或损伤,完成叶片的再制造,恢复叶片的使用性能。利用微束等离子焊接的方法在叶片顶端、叶片边沿熔覆堆焊金属,完成叶片顶端、叶片边沿磨损或损伤部位的熔覆堆焊;对叶片顶端、叶片边沿、叶片顶端熔覆堆焊部位进行电火花精整加工,最后利用湿吹沙工艺去除掉叶片电火花加工中出现的熔凝层,并对叶片进行抛光处理;将型面已经修复好的整体叶盘装在外圆磨床上,进行整体叶盘外圆高速磨削并达到叶片的长度尺寸,完成整体叶盘叶片顶部、叶片边沿磨损或损伤的修复工作。其相对于现有技术,具有以下有益效果:The purpose of the present invention is to provide a whole blisk blade repair technology based on micro-beam plasma welding and electric spark finishing, which can quickly and accurately repair the wear or damage of the blade tip and blade edge on the basis of the blade profile, and complete the blade The remanufacturing of the blade restores the performance of the blade. Use the method of micro-beam plasma welding to clad and surfacing metal on the tip of the blade and the edge of the blade to complete the cladding and surfacing of the worn or damaged parts of the tip of the blade and the edge of the blade; EDM finishing, and finally use the wet sand blowing process to remove the fused layer that appeared in the EDM of the blade, and polish the blade; install the whole leaf disc with the repaired profile on the cylindrical grinder, and carry out the overall The outer circle of the blisk is ground at high speed to reach the length of the blade, and the repair work of the top of the blisk blade and the edge of the blade is worn or damaged. Compared with the prior art, it has the following beneficial effects:

1)微束等离子焊接电弧稳定性好,弧柱挺直度好,能量集中,温度高,焊接速度快,可节省焊接材料,焊接熔覆层致密,可提高焊接修复质量和性能。1) Micro-beam plasma welding has good arc stability, good arc column straightness, concentrated energy, high temperature and fast welding speed, which can save welding materials, and the welding cladding layer is dense, which can improve the quality and performance of welding repair.

2)电火花加工可提高加工精度、缩短加工周期、降低加工成本,实现加工过程的数字化控制。电火花加工技术与传统的铣削、磨削加工技术相比不受材料强度、硬度、等因素的影响,加工过程中不存在切削力以及切削热的影响,因此对于整体叶盘叶片顶端磨损部位熔覆堆焊后的精加工电火花加工有明显优势。2) EDM can improve the machining accuracy, shorten the machining cycle, reduce the machining cost, and realize the digital control of the machining process. Compared with traditional milling and grinding technology, EDM technology is not affected by material strength, hardness, and other factors. There is no cutting force and cutting heat in the processing process. Finishing EDM after overlay welding has obvious advantages.

3)经过上述步骤之后就可以快速实现整体叶盘叶片顶端磨损部位的修复工作,此工艺相比人工焊接和手工打磨有很大的优势,有利于实现整体叶盘修复的自动化,缩短修复时间,利于叶片型面的连续性,提高焊接修复整体叶盘的成品率。3) After the above steps, the repair of the worn part of the top of the blisk can be quickly realized. Compared with manual welding and manual grinding, this process has great advantages, which is conducive to realizing the automation of the repair of the blisk and shortening the repair time. It is beneficial to the continuity of the profile of the blade and improves the yield of the whole blisk by welding and repairing.

本发明的整体叶盘智能焊接、电火花精整技术,叶片焊接修复位置光学检测、自动生成焊接轨迹,由三轴机器人、两轴变位机系统自动完成堆焊,和手工焊接方法相比,不仅提高了焊接轨迹精度、质量,还可以提高功效5倍以上;堆焊部位的电火花精整,通过对叶片型面三维模型的分析,设计叶片型面电火花加工电极,同时考虑电火花电极的定位、进给路径,通过对堆焊形貌的测量,精确控制电火花加工量,与手工打磨、抛光相比,表面粗糙度可以达到Ra0.2以上,尺寸精度可以达到0.02mm,实现了叶片智能堆焊、电火花精整全数控加工过程,同时提高功效5倍以上。The intelligent welding of the whole blisk and the EDM finishing technology of the present invention, the optical detection of the blade welding repair position, the automatic generation of the welding track, and the automatic completion of the surfacing welding by the three-axis robot and the two-axis positioner system, compared with the manual welding method, It not only improves the accuracy and quality of the welding track, but also improves the efficiency by more than 5 times; for the EDM finishing of the surfacing welding part, through the analysis of the three-dimensional model of the blade surface, the EDM electrode for the blade surface is designed, and the EDM electrode is also considered The positioning and feed path of the surfacing welding can be precisely controlled by measuring the surface of the surfacing welding. Compared with manual grinding and polishing, the surface roughness can reach Ra0.2 or more, and the dimensional accuracy can reach 0.02mm. Blade intelligent surfacing, electric spark finishing full CNC machining process, while improving efficiency by more than 5 times.

【附图说明】【Description of drawings】

图1为本发明修复方法的流程图。Fig. 1 is a flowchart of the repair method of the present invention.

【具体实施方式】【detailed description】

请参阅图1所示,本发明基于微束等离子焊接和电火花精整的整体叶盘修复方法,包括以下步骤:Please refer to shown in Fig. 1, the present invention is based on micro-beam plasma welding and the overall blisk repair method of electric spark finishing, comprises the following steps:

1)清洗掉整体叶盘叶片表面的油污、锈蚀。把整体叶盘安装在变位机上,选取某个待修复叶片为基准,调整变位机姿态,使该叶片端面正对于线激光扫描器下方;1) Clean off the oil and rust on the surface of the blisk blades. Install the blisk on the positioner, select a blade to be repaired as a reference, and adjust the position of the positioner so that the end face of the blade is directly below the line laser scanner;

2)调整线激光扫描器,使其沿平行于该目标叶片磨损面方向移动得到整体叶盘叶片磨损部位轮廓的三维离散点,通过分割算法得到整体叶盘叶片磨损部位的焊接轨迹,保持变位机中整体叶盘的位姿不变,线激光扫描器退回到安全区域;2) Adjust the line laser scanner so that it moves in a direction parallel to the target blade wear surface to obtain the three-dimensional discrete points of the contour of the wear part of the blisk blade, and obtain the welding trajectory of the wear part of the blisk blade through a segmentation algorithm, keeping the displacement The pose of the blisk in the machine remains unchanged, and the line laser scanner returns to the safe area;

3)将步骤2)中扫描得到的焊接轨迹通过离线编程产生控制程序,并通过离线编程产生的程序控制控制焊接机器人和变位机同步协调运动,实现目标叶片磨损部位微束等离子熔覆堆焊;3) The welding trajectory scanned in step 2) is used to generate a control program through offline programming, and the program generated by offline programming is used to control the synchronous and coordinated movement of the welding robot and the positioner to achieve micro-beam plasma cladding surfacing on the worn part of the target blade ;

4)调整变位机姿态,使目标叶片的下一个磨损部位正对于线激光扫描器下方,线激光扫描器返回到扫描区域,重复步骤2)和步骤3),直至微束等离子熔覆堆焊完目标叶片的所有磨损部位;4) Adjust the posture of the positioner so that the next worn part of the target blade is directly below the line laser scanner, and the line laser scanner returns to the scanning area, repeating steps 2) and 3) until the micro-beam plasma cladding surfacing Complete all worn parts of the target blade;

5)变位机旋转一定角度,该角度为叶片在叶轮上的分布角度,以下一个磨损叶片为微束等离子熔覆堆焊目标,重复步骤2)—4),直到完成整体叶盘所有叶片磨损部位的微束等离子熔覆堆焊。5) The positioner rotates at a certain angle, which is the distribution angle of the blades on the impeller, and the next worn blade is the microbeam plasma cladding surfacing welding target, repeat steps 2)-4) until all blades of the overall blisk are worn Part of the micro-beam plasma cladding surfacing.

6)将步骤5)得到的热等静压处理后的整体叶盘放入到热等静压机中进行热等静压处理,消除焊后存在于金属中的内应力,提高叶片的塑性和强度,延长叶片蠕变断裂寿命;6) Put the whole blisk after the hot isostatic pressing treatment obtained in step 5) into a hot isostatic pressing machine and carry out hot isostatic pressing treatment to eliminate the internal stress existing in the metal after welding and improve the plasticity and durability of the blade. Strength, prolonging the creep fracture life of the blade;

7)将经步骤6)得到的热等静压处理后整体叶盘装夹到三坐标测量机中,并采用机械测量方式测量热等静压处理后的整体叶盘,完成叶盘、叶片表面完整的点云数据采集,建立热等静压处理后整体叶盘的实际三维模型;7) Clamp the whole blisk after the hot isostatic pressing treatment obtained in step 6) into a three-coordinate measuring machine, and measure the whole blisk after the hot isostatic pressing by a mechanical measurement method, and complete the blisk and blade surface Complete point cloud data collection, establish the actual 3D model of the whole blisk after hot isostatic pressing;

8)通过对比热等静压处理后整体叶盘的实际三维模型与整体叶盘的设计三维模型,得到热等静压处理后整体叶盘的实际三维模型相对于整体叶盘的设计三维模型的精度误差及变形量;8) By comparing the actual 3D model of the blisk after HIP treatment with the design 3D model of the blisk, the difference between the actual 3D model of the blisk after HIP treatment and the design 3D model of the blisk is obtained. Accuracy error and deformation;

9)根据步骤8)得到的精度误差及变形量,确定电火花加工余量;9) According to the precision error and the amount of deformation obtained in step 8), determine the EDM allowance;

10)根据叶盘叶片的设计三维模型,采用“反拷”的办法来获取叶片仿形阴极,设计电火花加工电极。10) According to the design three-dimensional model of the blisk blade, adopt the method of "reverse copy" to obtain the profiling cathode of the blade, and design the EDM electrode.

11)把经过步骤6)处理得到的热等静压处理后整体叶盘装夹到五轴电火花加工机床的工作台上,根据步骤9)得到的加工余量和步骤10)设计的电火花加工电极对热等静压处理后的整体叶盘进行电火花加工,得到修复后整体叶盘;11) Clamp the blisk after the hot isostatic pressing treatment obtained in step 6) onto the workbench of the five-axis EDM machine tool, and according to the machining allowance obtained in step 9) and the EDM designed in step 10) The machining electrode conducts electric discharge machining on the blisk after hot isostatic pressing to obtain the blisk after repair;

步骤11)具体为:选择五轴联动电火花机床,针对整体叶盘叶片顶端的熔覆焊接部位,选择电火花加工电极沿叶间通道径向接近路径,到达精整加工位置,采用切向进给方式,对叶片的叶盆、叶背分别进行电火花精整加工;针对整体叶盘叶片边沿的熔覆焊接部位,选择轴向接近路径,到达加工部位,采用沿垂直于叶片边沿面的法向进给方式,对叶片的两侧边沿分别进行电火花精整加工。Step 11) is specifically: select a five-axis linkage EDM machine tool, aiming at the cladding and welding part of the top of the overall blisk blade, select the EDM electrode to approach the path radially along the inter-blade passage, and reach the finishing position, and use tangential cutting In this way, the blade pot and blade back of the blade are respectively subjected to EDM finishing; for the cladding welding part of the edge of the overall blisk blade, the axial approach path is selected to reach the processing part, and the method is adopted along the vertical direction of the blade edge surface. In the feed mode, the edges on both sides of the blade are respectively subjected to EDM finishing.

12)将经步骤11)得到的修复后整体叶盘装夹到三坐标测量机中,并采用机械测量方式测量修复后整体叶盘,建立修复后整体叶盘的实际三维模型;然后将修复后整体叶盘的实际三维模型与设计三维模型进行对比,得到修复后整体叶盘的最终精度误差及最终变形量;12) Clamp the repaired blisk obtained in step 11) into a three-coordinate measuring machine, measure the repaired blisk by mechanical measurement, and establish an actual three-dimensional model of the repaired blisk; The actual 3D model of the blisk is compared with the design 3D model to obtain the final accuracy error and final deformation of the blisk after repair;

13)根据修复后整体叶盘的最终精度误差及最终变形量判断整体叶盘是否合格;当不合格时,重复步骤7)—9)及步骤11);当合格时,则采用湿吹沙、振动光饰和喷丸工艺对修复后的整体叶盘进行表面处理,然后再对修复后整体叶盘的叶片顶端进行外圆磨削,达到叶片的长度尺寸,得到修复的整体叶盘。13) According to the final accuracy error and final deformation of the overall blisk after repair, judge whether the overall blisk is qualified; if unqualified, repeat steps 7)-9) and step 11); when qualified, use wet sand blowing, Vibration finishing and shot peening process are used to surface-treat the repaired blisk, and then the top of the blade is cylindrically ground to reach the length of the blade, and the repaired blisk is obtained.

14)对修复的整个叶盘叶片进行无损探伤后,最后进行大功率试车。14) After non-destructive testing of the repaired blisk blades, a high-power test run is finally carried out.

步骤2)具体为:Step 2) is specifically:

线激光扫描器沿平行于叶片顶端面方向以速度V移动,且由式V=Df确定。其中:V为线激光扫描器扫描速度,单位为mm/s;D为线激光扫描器扫描精度,单位为mm,和获取叶片顶端三维离散点轮廓的数据精度有关;f为线激光扫描器扫描频率,单位为Hz。通过线激光扫描器获取整体叶盘叶片顶端两条轮廓的三维离散点,通过(xi,yi,zi)={(x1i+x2i)/(n+1),(y1i+y2i)/(n+1),(z1i+z2i)/(n+1)},可以得到整体叶盘叶片顶端磨损焊接修复轨迹,其中(xi,yi,zi)为焊接修复轨迹离散点,(x1i,y1i,z1i)和(x2i,y2i,z2i)为整体叶盘叶片顶端两条轮廓的三维离散点,n为焊接修复的焊道数。The line laser scanner moves at a speed V in a direction parallel to the top surface of the blade, and is determined by the formula V=Df. Among them: V is the scanning speed of the line laser scanner, the unit is mm/s; D is the scanning accuracy of the line laser scanner, the unit is mm, which is related to the data accuracy of obtaining the three-dimensional discrete point profile at the top of the blade; f is the scanning speed of the line laser scanner Frequency, in Hz. The three-dimensional discrete points of the two contours at the top of the blade of the overall blisk are obtained by the line laser scanner, and ( xi , y i , z i )={(x 1i +x 2i )/(n+1), (y 1i + y 2i )/(n+1), (z 1i +z 2i )/(n+1)}, we can get the wear and welding repair track of the blade tip of the blisk, where ( xi , y i , z i ) is the welding The discrete points of the repair trajectory, (x 1i , y 1i , z 1i ) and (x 2i , y 2i , z 2i ) are the three-dimensional discrete points of the two contours at the top of the blisk blade, and n is the number of weld passes for welding repair.

步骤3)中微束等离子熔覆堆焊参数具体为:Step 3) The parameters of micro-beam plasma cladding and surfacing welding are specifically:

压缩喷嘴直径:0.6~1.2mm;焊接速度:0.25~0.65cm·s-1;焊接电流:5~16A;焊接电压:22~35V;氩气保护气体流量为24~36L·h-1;送粉速率为3-10g·s-1Compression nozzle diameter: 0.6~1.2mm; Welding speed: 0.25~ 0.65cm ·s -1 ; Welding current: 5~16A; Welding voltage: 22~35V; The powder rate is 3-10 g·s -1 .

步骤6)具体为:Step 6) is specifically:

将焊接修复得到的整体叶盘坯体放入到热等静压机中,加热到940℃,并加压到200MPa,保温恒压1h;然后冷却至650℃,并减压至110MPa,再保温恒压2-4h;最后再冷却至500℃,并减压至大气压,然后再随炉冷却至室温。Put the blisk body obtained by welding and repairing into a hot isostatic press, heat it to 940°C, pressurize it to 200MPa, keep it at constant pressure for 1h; then cool it down to 650°C, decompress it to 110MPa, and keep it warm Constant pressure for 2-4h; finally cooled to 500 ° C, and reduced to atmospheric pressure, and then cooled to room temperature with the furnace.

步骤7)的具体操作为:The concrete operation of step 7) is:

采用机械测量方式(手动编程加上自动测量)可以完成焊接修复叶片形面数据点的精确测量,得到足够多的叶片形面点云数据。The mechanical measurement method (manual programming plus automatic measurement) can complete the accurate measurement of the data points of the welded repaired blade surface, and obtain enough point cloud data of the blade surface.

步骤11)的具体操作为:The concrete operation of step 11) is:

将整体叶盘坯体水平安装在五轴联动电火花机床的变位机工作台上,采用煤油工作液、紫铜材质的球状或圆柱工具电极,设置整体叶盘的极性为正极,选用等能量方波的电源模式,设置电火花机床参数后根据电火花加工余量分别对整体叶盘叶片顶端和叶片边沿进行电火花精整加工;Install the blisk body horizontally on the positioner workbench of the five-axis linkage EDM machine tool, use kerosene working fluid, and spherical or cylindrical tool electrodes made of copper, set the polarity of the blisk to positive, and use equal energy Square wave power supply mode, after setting the parameters of the EDM machine tool, perform EDM finishing on the top of the overall blisk blade and the edge of the blade according to the EDM allowance;

所述电火花铣削机床参数为:脉冲宽度为5-30μs,脉冲间隙为15-40μs,电流密度为17.52-84.39A/cm2,间隙电压为35-70V。The parameters of the electric spark milling machine tool are: pulse width 5-30μs, pulse gap 15-40μs, current density 17.52-84.39A/cm 2 , gap voltage 35-70V.

步骤13)中对整体叶盘样品进行磨削的具体过程为:将整体叶盘样品安装到外圆磨床上,通过外圆磨床对整体叶盘样品上叶片的端面进行磨削,磨削过程中,整体叶盘样品的转速为6000r/min,砂轮线速度为120m/s,纵向进给速度为0.01mm/min,外圆磨床采用水基冷却方式注水,其中,水的流量为90L/min、扬程为5.5m。The specific process of grinding the blisk sample in step 13) is: the blisk sample is installed on the cylindrical grinder, and the end face of the blade on the blisk sample is ground by the cylindrical grinder, during the grinding process , the rotational speed of the blisk sample is 6000r/min, the linear speed of the grinding wheel is 120m/s, the longitudinal feed speed is 0.01mm/min, and the cylindrical grinder adopts water-based cooling method to inject water, wherein the flow rate of water is 90L/min, The head is 5.5m.

Claims (5)

  1. A kind of 1. repairing method of solid impeller disc based on MICROBEAM PLASMA WELDING and electric spark finishing, it is characterised in that including with Lower step:
    1) blisk is arranged on positioner, on the basis of choosing a blade to be repaired, adjusts positioner posture, make the leaf Piece end face is right against below line laser scanner;
    2) line laser scanner is adjusted, makes its edge move to obtain integrated impeller blade mill parallel to the target blade wear face direction The 3 d-dem point of position profile is damaged, the welding track of integrated impeller blade abrading section is obtained by partitioning algorithm;
    3) welding track that scanning obtains in step 2) is produced into control program by off-line programing, and produced by off-line programing Programme-control control welding robot and positioner synchronous coordination motion, realize that target blade wear position microplasma melts Cover built-up welding;
    4) positioner posture is adjusted, next abrading section of target blade is right against below line laser scanner;Repeat to walk It is rapid 2) and step 3), until microplasma cladding heap is soldered all abrading sections of target blade;
    5) positioner rotates to an angle, and the angle is distribution angle of the blade on impeller, using next abrasion blade to be micro- Beam plasma cladding built-up welding target, repeat step 2) -4), microbeam until completing all blade wear positions of blisk etc. Ion cladding built-up welding;
    6) blisk for the microplasma cladding heap postwelding that step 5) obtains is put into hot isostatic press and carries out heat etc. Static pressure processing;
    7) into three coordinate measuring machine, high temperature insostatic pressing (HIP) will be measured by blisk clamping after the hip treatment that step 6) obtains Blisk after processing, the complete cloud data collection of leaf dish, blade surface is completed, establishes overall leaf after hip treatment The actual threedimensional model of disk;
    8) by contrasting the design threedimensional model of the actual threedimensional model and blisk of blisk after hip treatment, obtain After to hip treatment the actual threedimensional model of blisk relative to blisk design threedimensional model trueness error And deflection;
    9) trueness error and deflection obtained according to step 8), determines electrical discharge machining surplus;
    10) threedimensional model is designed according to impeller blade, obtains blade profiling negative electrode, design electric discharging machining electrode;
    11) blisk clamping after the hip treatment obtained by step 6) processing to five axle electric spark machine tools On workbench, the electric discharging machining electrode of allowance and step 10) design obtained according to step 9) is to hip treatment Blisk afterwards carries out electrical discharge machining, blisk after being repaired;
    12) into three coordinate measuring machine, overall leaf after repairing will be measured by blisk clamping after the reparation that step 11) obtains Disk, establish the actual threedimensional model of blisk after repairing;Then by the actual threedimensional model of blisk after reparation and design Threedimensional model is contrasted, the final trueness error and final deformation amount of blisk after being repaired;
    13) judge whether blisk is qualified according to the final trueness error of blisk after reparation and final deformation amount;When not When qualified, repeat step 7) -9) and step 11);When qualified, then using it is wet blow sand, vibration finishing and shot-blast process be to repairing Blisk afterwards is surface-treated, and is then carried out cylindricalo grinding to the blade tip of blisk after reparation again, is reached leaf The length dimension of piece, the blisk repaired;
    Step 2) is specially:Line laser scanner edge is moved parallel to blade tip face direction with speed V, and true by Formula V=Df It is fixed;Wherein:V is line laser scanner sweep speed, unit mm/s;D is line laser scanner scanning accuracy, unit mm, It is relevant with the data precision for obtaining blade tip 3 d-dem dot profile;F is line laser scanner scan frequency, unit Hz; The 3 d-dem point of two, top of integrated impeller blade profile is obtained by line laser scanner, passes through (xi,yi,zi)={ (x1i+ x2i)/(n+1), (y1i+y2i)/(n+1), (z1i+z2i)/(n+1) }, obtain integrated impeller blade top abrasion REPAIR WELDING rail Mark, wherein (xi,yi,zi) it is REPAIR WELDING track discrete point, (x1i,y1i,z1i) and (x2i,y2i,z2i) it is integrated impeller blade top The 3 d-dem point of two profiles is held, n is the number of weld passes of REPAIR WELDING;
    Microplasma cladding built-up welding parameter is specially in step 3):Constricting nozzle diameter:0.6~1.2mm;Speed of welding: 0.25~0.65cms-1;Welding current:5~16A;Weldingvoltage:22~35V;Argon gas shield gas flow rate is 24~36L h-1;Powder feeding rate is 3-10gs-1
  2. 2. the repairing method of solid impeller disc according to claim 1 based on MICROBEAM PLASMA WELDING and electric spark finishing, its It is characterised by, it is further comprising the steps of:
    14) after carrying out nondestructive inspection to the whole impeller blade that step 13) is repaired, high-power test run is finally carried out.
  3. 3. the repairing method of solid impeller disc according to claim 1 based on MICROBEAM PLASMA WELDING and electric spark finishing, its It is characterised by, step 6) is specially:The blisk base substrate that REPAIR WELDING obtains is put into hot isostatic press, is heated to 940 DEG C, and 200MPa is pressurized to, insulation constant pressure 1h;650 DEG C are subsequently cooled to, and is decompressed to 110MPa, then is incubated constant pressure 2- 4h;500 DEG C are finally cooled to, and is decompressed to atmospheric pressure, then cools to room temperature with the furnace again.
  4. 4. the repairing method of solid impeller disc according to claim 1 based on MICROBEAM PLASMA WELDING and electric spark finishing, its It is characterised by, the concrete operations of step 11) are:Blisk base substrate is horizontally arranged to the displacement of five-axle linkage spark-erosion machine tool On machine worktable, using kerosene working solution, the spherical or cylindrical tool electrode of red copper material, the polarity of blisk is set for just Pole, from etc. energy square wave electric source modes, set electric spark milling lathe parameter after it is right respectively according to electrical discharge machining surplus Integrated impeller blade top and blade edge edge carry out electric spark finished machined;Electric spark milling lathe parameter is:Pulse width is 5-30 μ s, inter-train pause are 15-40 μ s, current density 17.52-84.39A/cm2, gap voltage 35-70V.
  5. 5. the repairing method of solid impeller disc according to claim 1 based on MICROBEAM PLASMA WELDING and electric spark finishing, its It is characterised by, the detailed process being ground in step 13) to blisk sample is:Blisk sample is installed to cylindrical On grinding machine, the end face of blisk sample blade is ground by cylindrical grinder, in grinding process, blisk sample Rotating speed be 6000r/min, grinding speed 120m/s, length feed speed is 0.01mm/min, and cylindrical grinder uses water Base type of cooling water filling, wherein, the flow of water is 90L/min, lift 5.5m.
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