CN118305383A - Precise electrolytic machining device and method for blisk with air insulation protection narrow channel - Google Patents
Precise electrolytic machining device and method for blisk with air insulation protection narrow channel Download PDFInfo
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- CN118305383A CN118305383A CN202410505747.6A CN202410505747A CN118305383A CN 118305383 A CN118305383 A CN 118305383A CN 202410505747 A CN202410505747 A CN 202410505747A CN 118305383 A CN118305383 A CN 118305383A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23H—WORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
- B23H3/00—Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
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Abstract
本发明提供一种气绝缘保护狭窄通道整体叶盘精密电解加工装置及方法,本发明电解加工装置包括机床固定组件、叶盘定位夹紧组件、L型阴极组件、气绝缘保护组件,机床固定组件包括机床竖直主轴、机床第一主轴、机床第二主轴;叶盘定位夹紧装置固定于机床竖直主轴上,在加工前可将整体叶盘移动至合适位置,满足狭窄通道整体叶盘的加工需求;L型阴极装置固定于机床第一主轴、机床第二主轴上,其内部设有通道供电解液流过,L型阴极设计在加工叶片的同时对叶盘轮毂进行加工,减少了后续加工步骤,提高加工效率;气绝缘保护组件固定于L型阴极组件上,在加工过程中通入高压气体,防止电解液对相邻叶片的杂散腐蚀,提高了整体叶盘加工精度。
The present invention provides a precision electrolytic machining device and method for an integral blade disk with a narrow channel protected by air insulation. The electrolytic machining device of the present invention comprises a machine tool fixing component, a blade disk positioning and clamping component, an L-shaped cathode component, and a gas insulation protection component. The machine tool fixing component comprises a vertical spindle of the machine tool, a first spindle of the machine tool, and a second spindle of the machine tool. The blade disk positioning and clamping device is fixed on the vertical spindle of the machine tool, and the integral blade disk can be moved to a suitable position before machining to meet the machining requirements of the integral blade disk with a narrow channel. The L-shaped cathode device is fixed on the first spindle and the second spindle of the machine tool, and a channel is provided inside the L-shaped cathode device for electrolyte to flow through. The L-shaped cathode design processes the blade disk hub while machining the blades, thereby reducing subsequent machining steps and improving machining efficiency. The gas insulation protection component is fixed on the L-shaped cathode component, and high-pressure gas is introduced during machining to prevent stray corrosion of adjacent blades by the electrolyte, thereby improving the machining precision of the integral blade disk.
Description
技术领域Technical Field
本发明属于数控电解加工技术领域,具体涉及气绝缘保护狭窄通道整体叶盘精密电解加工装置及方法。The invention belongs to the technical field of numerically controlled electrolytic machining, and in particular relates to a device and method for precision electrolytic machining of an integral blade disk with a narrow passage protected by gas insulation.
背景技术Background technique
整体叶盘和传统叶片与轮盘组合式结构相比,消除了因榫槽连接造成的气流损失,大大减轻了零件重量,使得发动机结构大为简化,提高了功重比,延长了使用寿命,是新型航空发动机的核心部件。Compared with the traditional blade and disc combined structure, the integral blisk eliminates the airflow loss caused by the tongue and groove connection, greatly reduces the weight of parts, greatly simplifies the engine structure, improves the power-to-weight ratio, and extends the service life. It is the core component of the new aircraft engine.
电解加工是一种基于电化学阳极腐蚀的加工方法,与传统方法相比具有加工表面质量好、加工不受材料力学性能限制、加工效率高、加工后工件表面无残余应力、工具阴极理论上不损耗等优点,被认为是加工整体叶盘的有效方法。Electrolytic machining is a machining method based on electrochemical anodic corrosion. Compared with traditional methods, it has the advantages of good machining surface quality, machining is not limited by the mechanical properties of the material, high machining efficiency, no residual stress on the workpiece surface after machining, and theoretically no tool cathode loss. It is considered to be an effective method for machining integral blades.
随着新型发动机对于功重比的更高要求,整体叶盘呈叶片更薄、更弯、截面变化更大且通道更加狭窄的发展趋势,且多采用高温合金钛合金等难加工材料,使其加工制造困难。整体叶盘电解加工分为两步,分别是通道粗加工和叶身精加工,叶身精加工最终决定整体叶盘的加工精度。With the new engine's higher requirements for power-to-weight ratio, the integral blade disk has a trend of thinner and more curved blades, larger cross-section changes and narrower channels. It is also made of high-temperature alloy titanium alloy and other difficult-to-process materials, making it difficult to process and manufacture. The electrolytic machining of the integral blade disk is divided into two steps, namely channel rough machining and blade body fine machining. The blade body fine machining ultimately determines the machining accuracy of the integral blade disk.
在整体叶盘精密电解加工中,加工过程会对相邻叶片造成杂散腐蚀,不利于高精度加工的进行,传统方法采用在相邻叶片套入与叶片形状相仿绝缘套的方法以防止杂散腐蚀,该方法在针对等截面弯扭角度为零的叶片时具有一定作用,但是每次加工都需要人工套入绝缘套作业,不符合高效加工的需求。当叶片弯扭程度大且通道狭窄时,采用套入绝缘套的方法无法满足实际需求,因此需要研究一种新型的加工过程中对相邻叶片的绝缘保护方式,以提高加工精度及加工效率。In the precision electrolytic machining of integral blades, the machining process will cause stray corrosion to adjacent blades, which is not conducive to high-precision machining. The traditional method uses the method of inserting an insulating sleeve with a similar shape to the adjacent blades to prevent stray corrosion. This method has a certain effect when targeting blades with equal cross-sectional bending and torsion angles of zero, but each machining requires manual insertion of the insulating sleeve, which does not meet the requirements of efficient machining. When the blade is bent and twisted to a large extent and the channel is narrow, the method of inserting the insulating sleeve cannot meet the actual needs. Therefore, it is necessary to study a new method of insulating and protecting adjacent blades during the machining process to improve machining accuracy and efficiency.
在以往的整体叶片精密电解加工工艺中,经过电解粗加工和精加工后,往往需要搭配铣削来进行整体叶盘轮毂处的加工,为减少加工工序需要研究一种可同时加工叶身和叶盘轮毂的电解加工方法,提高整体加工效率。In the previous precision electrolytic machining process of integral blades, after electrolytic rough machining and fine machining, milling is often required to carry out machining of the integral impeller hub. In order to reduce the machining process, it is necessary to study an electrolytic machining method that can simultaneously process the blade body and the impeller hub to improve the overall machining efficiency.
发明内容Summary of the invention
发明目的:本发明提供了一种提高狭窄通道整体叶盘的加工效率及加工精度的气绝缘保护狭窄通道整体叶盘精密电解加工装置及方法。Purpose of the invention: The present invention provides a device and method for precision electrolytic machining of an integral blade disk with air insulation protection for narrow channels, which can improve the machining efficiency and machining accuracy of the integral blade disk with narrow channels.
技术方案:一种气绝缘保护狭窄通道整体叶盘精密电解加工装置,包括机床固定组件、叶盘定位夹紧组件、L型阴极组件、气绝缘保护组件,Technical solution: A precision electrolytic machining device for a gas-insulated narrow channel integral blade disk, including a machine tool fixing component, a blade disk positioning and clamping component, an L-shaped cathode component, and a gas-insulated protection component.
具体地,机床固定组件包括机床竖直主轴、机床第一主轴、机床第二主轴,所述叶盘定位夹紧组件固定于机床竖直主轴上,所述气绝缘保护组件固定于L型阴极组件上;Specifically, the machine tool fixing assembly includes a machine tool vertical spindle, a machine tool first spindle, and a machine tool second spindle, the blade disk positioning clamping assembly is fixed on the machine tool vertical spindle, and the gas insulation protection assembly is fixed on the L-shaped cathode assembly;
具体地,所述叶盘定位夹紧组件包括叶盘定位柱、叶盘夹紧座,所述叶盘定位柱为可转动的,且固定于机床竖直主轴上,所述叶盘夹紧座固定于叶盘定位柱上;Specifically, the blade disc positioning and clamping assembly includes a blade disc positioning column and a blade disc clamping seat, the blade disc positioning column is rotatable and fixed on the vertical spindle of the machine tool, and the blade disc clamping seat is fixed on the blade disc positioning column;
具体地,所述L型阴极组件包括第一L型立体曲面阴极、第二L型立体曲面阴极、通液柱、通液接头、第一阴极定位夹紧座、第二阴极定位夹紧座,所述第一阴极定位夹紧座、第二阴极定位夹紧座分别固定于机床第一主轴、第二主轴上,所述第一L型立体曲面阴极、第二L型立体曲面阴极分别定位于第一阴极定位夹紧座、第二阴极定位夹紧座上,所述通液柱固定于第一阴极定位夹紧座上,所述通液接头安装在通液柱上;Specifically, the L-shaped cathode assembly includes a first L-shaped three-dimensional curved cathode, a second L-shaped three-dimensional curved cathode, a liquid-through column, a liquid-through joint, a first cathode positioning clamping seat, and a second cathode positioning clamping seat. The first cathode positioning clamping seat and the second cathode positioning clamping seat are respectively fixed to the first spindle and the second spindle of the machine tool. The first L-shaped three-dimensional curved cathode and the second L-shaped three-dimensional curved cathode are respectively positioned on the first cathode positioning clamping seat and the second cathode positioning clamping seat. The liquid-through column is fixed on the first cathode positioning clamping seat, and the liquid-through joint is installed on the liquid-through column.
具体地,所述气绝缘保护组件包括第一阴极通气柱、第二阴极通气柱、第一阴极通气接口、第二阴极通气接口、第一气体换向座、第二气体换向座、第一阴极气体末端导流块、第二阴极气体末端导流块,所述第一阴极通气柱、第二阴极通气柱分别固定于第一阴极定位夹紧座、第二阴极定位夹紧座上,所述第一阴极通气接口、第二阴极通气接口分别安装于第一阴极通气柱、第二阴极通气柱上,所述第一气体换向座、第二气体换向座分别固定于第一阴极定位夹紧座、第二阴极定位夹紧座上,所述第一阴极气体末端导流块、第二阴极气体末端导流块分别固定于第一L型立体曲面阴极、第二L型立体曲面阴极上。Specifically, the gas insulation protection component includes a first cathode ventilation column, a second cathode ventilation column, a first cathode ventilation interface, a second cathode ventilation interface, a first gas reversing seat, a second gas reversing seat, a first cathode gas end guide block, and a second cathode gas end guide block. The first cathode ventilation column and the second cathode ventilation column are respectively fixed on the first cathode positioning clamping seat and the second cathode positioning clamping seat, the first cathode ventilation interface and the second cathode ventilation interface are respectively installed on the first cathode ventilation column and the second cathode ventilation column, the first gas reversing seat and the second gas reversing seat are respectively fixed on the first cathode positioning clamping seat and the second cathode positioning clamping seat, the first cathode gas end guide block and the second cathode gas end guide block are respectively fixed on the first L-shaped three-dimensional curved cathode and the second L-shaped three-dimensional curved cathode.
更进一步地,所述狭窄通道整体叶盘包括叶片、叶盘轮毂。Furthermore, the narrow channel integral blade disk includes blades and a blade disk hub.
更进一步地,所述叶盘定位夹紧组件还包括叶盘前端绝缘盖、叶盘后端绝缘盖,所述叶盘前端绝缘盖固定于叶盘夹紧座上,所述叶盘后端绝缘盖固定于叶盘定位柱上。Furthermore, the blade disc positioning and clamping assembly also includes a blade disc front end insulation cover and a blade disc rear end insulation cover, the blade disc front end insulation cover is fixed on the blade disc clamping seat, and the blade disc rear end insulation cover is fixed on the blade disc positioning column.
更进一步地,所述叶盘前端绝缘盖、叶盘后端绝缘盖覆盖于狭窄通道整体叶盘非加工区域。Furthermore, the insulation cover at the front end of the blade disk and the insulation cover at the rear end of the blade disk cover the non-processing area of the entire blade disk in the narrow channel.
更进一步地,所述第一阴极定位夹紧座、第二阴极定位夹紧座分别通过第一快换夹头、第二快换夹头固定于机床第一主轴、机床第二主轴上。Furthermore, the first cathode positioning clamping seat and the second cathode positioning clamping seat are fixed to the first spindle and the second spindle of the machine tool through a first quick-change chuck and a second quick-change chuck respectively.
更进一步地,所述L型阴极组件还包括第一阴极叶尖处绝缘套、第二阴极叶尖处绝缘套,所述第一阴极叶尖处绝缘套、第二阴极叶尖处绝缘套分别固定于第一L型立体曲面阴极、第二L型立体曲面阴极上。Furthermore, the L-shaped cathode assembly also includes an insulating sleeve at the first cathode blade tip and an insulating sleeve at the second cathode blade tip, and the first insulating sleeve at the cathode blade tip and the second insulating sleeve at the cathode blade tip are respectively fixed on the first L-shaped three-dimensional curved cathode and the second L-shaped three-dimensional curved cathode.
更进一步地,所述气绝缘保护组件还包括第一牺牲阳极保护板、第二牺牲阳极保护板,所述第一牺牲阳极保护板、第二牺牲阳极保护板分别固定于第一气体换向座、第二气体换向座上。Furthermore, the gas insulation protection assembly also includes a first sacrificial anode protection plate and a second sacrificial anode protection plate, and the first sacrificial anode protection plate and the second sacrificial anode protection plate are fixed on the first gas reversing seat and the second gas reversing seat respectively.
更进一步地,所述第一L型立体曲面阴极、第二L型立体曲面阴极的上端面为与所述叶盘轮毂为形状互补的结构。Furthermore, the upper end surfaces of the first L-shaped three-dimensional curved surface cathode and the second L-shaped three-dimensional curved surface cathode are structures with complementary shapes to the blade disk hub.
更进一步地,所述第一阴极通气柱、第一阴极通气接口、第一气体换向座与第二阴极通气柱、第二阴极通气接口、第二气体换向座分别构成两条气绝缘保护流道。Furthermore, the first cathode ventilation column, the first cathode ventilation interface, the first gas reversing seat and the second cathode ventilation column, the second cathode ventilation interface, the second gas reversing seat respectively form two gas insulation protection flow channels.
本发明同时提供上述气绝缘保护狭窄通道整体叶盘精密电解加工方法,包括以下步骤:The present invention also provides a method for precision electrochemical machining of the above-mentioned air-insulated protection narrow channel integral blade disk, comprising the following steps:
(1)将第一快换夹头、第二快换夹头分别固定于机床第一主轴、机床第二主轴上,之后将第一阴极定位夹紧座、第二阴极定位夹紧座分别安装在第一快换夹头、第二快换夹头上,随后将第一L型立体曲面阴极、第二L型立体曲面阴极分别安装在第一阴极定位夹紧座、第二阴极定位夹紧座上,再将第一阴极叶尖处绝缘套、第二阴极叶尖处绝缘套分别安装在第一L型立体曲面阴极、第二L型立体曲面阴极上,最后将通液柱安装在第一阴极定位夹紧座上,将通液接头接在通液柱上;(1) Fix the first quick-change chuck and the second quick-change chuck on the first spindle and the second spindle of the machine tool respectively, then install the first cathode positioning clamping seat and the second cathode positioning clamping seat on the first quick-change chuck and the second quick-change chuck respectively, then install the first L-shaped three-dimensional curved surface cathode and the second L-shaped three-dimensional curved surface cathode on the first cathode positioning clamping seat and the second cathode positioning clamping seat respectively, then install the insulating sleeve at the tip of the first cathode and the insulating sleeve at the tip of the second cathode on the first L-shaped three-dimensional curved surface cathode and the second L-shaped three-dimensional curved surface cathode respectively, finally install the liquid column on the first cathode positioning clamping seat, and connect the liquid connection joint to the liquid column;
(2)将第一阴极通气柱、第二阴极通气柱及第一气体换向座、第二气体换向座分别固定于第一阴极定位夹紧座、第二阴极定位夹紧座上,之后将第一阴极气体末端导流块、第二阴极气体末端导流块分别固定于第一L型立体曲面阴极、第二L型立体曲面阴极上,随后将第一牺牲阳极保护板、第二牺牲阳极保护板分别固定于第一气体换向座、第二气体换向座上,最后将第一阴极通气接口、第二阴极通气接口安装在第一阴极通气柱、第二阴极通气柱上;(2) The first cathode ventilation column, the second cathode ventilation column and the first gas reversing seat, the second gas reversing seat are fixed to the first cathode positioning clamping seat, the second cathode positioning clamping seat, and then the first cathode gas terminal guide block, the second cathode gas terminal guide block are fixed to the first L-shaped three-dimensional curved cathode, the second L-shaped three-dimensional curved cathode, and then the first sacrificial anode protection plate, the second sacrificial anode protection plate are fixed to the first gas reversing seat, the second gas reversing seat, and finally the first cathode ventilation interface, the second cathode ventilation interface are installed on the first cathode ventilation column, the second cathode ventilation column;
(3)将狭窄通道整体叶盘安装在叶盘定位柱上,之后将叶盘后端绝缘盖安装在叶盘定位柱上,叶盘夹紧座固定于叶盘定位柱上,叶盘前端面绝缘盖固定于叶盘夹紧座上,最后将叶盘定位柱固定于机床竖直主轴上;(3) Install the narrow channel integral blade disk on the blade disk positioning column, then install the insulation cover at the rear end of the blade disk on the blade disk positioning column, fix the blade disk clamping seat on the blade disk positioning column, fix the insulation cover at the front end of the blade disk on the blade disk clamping seat, and finally fix the blade disk positioning column on the vertical spindle of the machine tool;
(4)启动电解加工机床,启动机床加热系统进行预热,待电解液加工至25~30℃,启动电解液恒温系统;(4) Start the electrolytic machining machine, start the machine heating system for preheating, wait for the electrolyte to reach 25-30°C, and start the electrolyte constant temperature system;
(5)将狭窄通道整体叶盘与机床正极相连,将第一L型立体曲面阴极和第二L型立体曲面阴极与机床负极相连,将第一牺牲阳极保护板、第二牺牲阳极保护板与机床正极相连;(5) Connect the narrow channel integral blade disk to the positive electrode of the machine tool, connect the first L-shaped three-dimensional curved surface cathode and the second L-shaped three-dimensional curved surface cathode to the negative electrode of the machine tool, and connect the first sacrificial anode protection plate and the second sacrificial anode protection plate to the positive electrode of the machine tool;
(6)操控机床竖直主轴,使其按照设定好的轨迹移动至待加工的位置,随后进行预通液,检查通液装置密封性,然后停止通液,通入高压气体,检查气绝缘保护组件的密封性,操控机床第一主轴、机床第二主轴进行对刀,随后设置电解液参数;(6) Control the vertical spindle of the machine tool to move it to the position to be processed according to the set trajectory, then pre-flow the fluid, check the sealing of the fluid flow device, then stop the flow of fluid, pass high-pressure gas, check the sealing of the gas insulation protection component, control the first spindle and the second spindle of the machine tool to align the tool, and then set the electrolyte parameters;
(7)通入电解液及高压气体进行加工,在电化学阳极腐蚀作用下,留有一定余量的狭窄通道整体叶盘被加工成所需形状,加工完第一个叶片后停止通液,操控机床竖直主轴使狭窄通道整体叶盘离开加工区域,随后操控机床分度轴加工下一个叶片。(7) Electrolyte and high-pressure gas are introduced for processing. Under the action of electrochemical anode corrosion, the narrow channel integral blade disk with a certain margin is processed into the desired shape. After the first blade is processed, the liquid flow is stopped, the vertical spindle of the machine tool is controlled to make the narrow channel integral blade disk leave the processing area, and then the indexing axis of the machine tool is controlled to process the next blade.
(8)重复步骤(7)直至加工完狭窄通道整体叶盘所有叶片,随后停止通入电解液及高压气体,取出狭窄通道整体叶盘,关闭机床。(8) Repeat step (7) until all blades of the narrow channel integral blade disk are processed, then stop introducing electrolyte and high-pressure gas, remove the narrow channel integral blade disk, and turn off the machine tool.
有益效果:本发明气绝缘保护狭窄通道整体叶盘精密电解加工装置采用L型阴极设计,L型阴极顶部设计与轮毂外形相配合的阴极加工面,在加工狭窄通道整体叶盘叶片部分的同时对轮毂部分进行加工,在保证整体叶盘加工精度的同时,减少了后续加工步骤,提高了加工效率。本发明所述气绝缘保护狭窄通道整体叶盘精密电解加工方法使用高压气体将冲向相邻叶片叶根的液体进行阻断,防止电解液对于相邻叶片的杂散腐蚀,同时搭配牺牲阳极辅助阳极板对相邻叶片叶身进行保护,避免了人工重复安装绝缘组件,减少了操作人员工作量,提高了加工精度及生产效率。Beneficial effects: The precision electrolytic machining device for the gas-insulated narrow channel integral blade disk of the present invention adopts an L-shaped cathode design. The top of the L-shaped cathode is designed with a cathode machining surface that matches the hub shape. The hub part is processed while the blade part of the narrow channel integral blade disk is processed. While ensuring the machining accuracy of the integral blade disk, the subsequent machining steps are reduced, and the machining efficiency is improved. The precision electrolytic machining method for the gas-insulated narrow channel integral blade disk of the present invention uses high-pressure gas to block the liquid rushing toward the roots of adjacent blades to prevent stray corrosion of the electrolyte to adjacent blades. At the same time, a sacrificial anode auxiliary anode plate is used to protect the adjacent blade body, avoiding repeated manual installation of insulation components, reducing the workload of operators, and improving machining accuracy and production efficiency.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1是本发明狭窄通道整体叶盘结构示意图。FIG1 is a schematic diagram of the structure of a narrow channel integral blade disk of the present invention.
图2是本发明精密电解加工装置示意图。FIG. 2 is a schematic diagram of a precision electrolytic machining device according to the present invention.
图3是本发明精密电解加工装置L型阴极组件剖视图。FIG3 is a cross-sectional view of an L-shaped cathode assembly of a precision electrolytic machining device of the present invention.
图4是本发明精密电解加工装置L型阴极工作示意图。FIG. 4 is a schematic diagram of the operation of the L-shaped cathode of the precision electrolytic machining device of the present invention.
具体实施方式Detailed ways
下面结合附图和具体实施方式,进一步阐明本发明。The present invention is further explained below in conjunction with the accompanying drawings and specific implementation methods.
本发明公开了一种气绝缘保护狭窄通道整体叶盘精密电解加工装置,包括机床固定组件、叶盘定位夹紧组件、L型阴极组件、气绝缘保护组件,The invention discloses a precision electrolytic machining device for a gas-insulated protection narrow channel integral blade disk, comprising a machine tool fixing component, a blade disk positioning clamping component, an L-shaped cathode component, and a gas-insulated protection component.
如图1所示,狭窄通道整体叶盘1包括若干叶片29、叶盘轮毂30。As shown in FIG. 1 , the narrow channel integral blade disk 1 includes a plurality of blades 29 and a blade disk hub 30 .
如图2所示,机床固定组件包括机床竖直主轴10、机床第一主轴26、机床第二主轴27,所述叶盘定位夹紧组件固定于机床竖直主轴10上,所述L型阴极组件固定于机床第一主轴26、机床第二主轴27上,所述气绝缘保护组件固定于L型阴极组件上;As shown in FIG2 , the machine tool fixed assembly includes a machine tool vertical spindle 10, a machine tool first spindle 26, and a machine tool second spindle 27, the blade disk positioning clamping assembly is fixed on the machine tool vertical spindle 10, the L-shaped cathode assembly is fixed on the machine tool first spindle 26, the machine tool second spindle 27, and the gas insulation protection assembly is fixed on the L-shaped cathode assembly;
所述叶盘定位夹紧组件包括叶盘定位柱11、叶盘夹紧座3,叶盘前端绝缘盖2、叶盘后端绝缘盖12,所述叶盘定位柱11固定于机床竖直主轴10上,所述叶盘夹紧座3固定于叶盘定位柱11上,所述叶盘前端绝缘盖2固定于叶盘夹紧座3上,所述叶盘后端绝缘盖12固定于叶盘定位柱11上,叶盘前端绝缘盖2与叶盘后端绝缘盖12覆盖于狭窄通道整体叶盘1的非加工区域,起到保护作用。The blisk positioning and clamping assembly includes a blisk positioning column 11, a blisk clamping seat 3, a blisk front end insulation cover 2, and a blisk rear end insulation cover 12. The blisk positioning column 11 is fixed on the vertical spindle 10 of the machine tool, the blisk clamping seat 3 is fixed on the blisk positioning column 11, the blisk front end insulation cover 2 is fixed on the blisk clamping seat 3, and the blisk rear end insulation cover 12 is fixed on the blisk positioning column 11. The blisk front end insulation cover 2 and the blisk rear end insulation cover 12 cover the non-processing area of the narrow channel integral blisk 1 to play a protective role.
如图3所示,所述L型阴极组件包括第一L型立体曲面阴极25、第二L型立体曲面阴极22、通液柱6、通液接头7、第一阴极定位夹紧座16、第二阴极定位夹紧座5、第一阴极叶尖处绝缘套24、第二阴极叶尖处绝缘套21,所述第一阴极定位夹紧座16、第二阴极定位夹紧座5分别固定于机床第一主轴26、机床第二主轴27上,所述第一L型立体曲面阴极25、第二L型立体曲面阴极22分别定位于第一阴极定位夹紧座16、第二阴极定位夹紧座5上,所述通液柱6固定于第一阴极定位夹紧座16上,所述通液接头7安装在通液柱6上,所述第一阴极叶尖处绝缘套24、第二阴极叶尖处绝缘套21分别固定于第一L型立体曲面阴极25、第二L型立体曲面阴极22上,用于防止阴极非加工区域对叶片29的杂散腐蚀。As shown in Figure 3, the L-shaped cathode assembly includes a first L-shaped three-dimensional curved cathode 25, a second L-shaped three-dimensional curved cathode 22, a liquid column 6, a liquid joint 7, a first cathode positioning clamping seat 16, a second cathode positioning clamping seat 5, an insulating sleeve 24 at the first cathode blade tip, and an insulating sleeve 21 at the second cathode blade tip. The first cathode positioning clamping seat 16 and the second cathode positioning clamping seat 5 are respectively fixed on the first spindle 26 and the second spindle 27 of the machine tool. The first L-shaped three-dimensional curved cathode 25 and the second L-shaped three-dimensional curved cathode 22 are respectively positioned on the first cathode positioning clamping seat 16 and the second cathode positioning clamping seat 5. The liquid column 6 is fixed on the first cathode positioning clamping seat 16. The liquid joint 7 is installed on the liquid column 6. The first cathode blade tip insulating sleeve 24 and the second cathode blade tip insulating sleeve 21 are respectively fixed on the first L-shaped three-dimensional curved cathode 25 and the second L-shaped three-dimensional curved cathode 22, so as to prevent stray corrosion of the blade 29 by the non-processing area of the cathode.
如图3~4所示,所述气绝缘保护组件包括第一阴极通气柱15、第二阴极通气柱28、第一阴极通气接口18、第二阴极通气接口9、第一气体换向座14、第二气体换向座4、第一阴极气体末端导流块23、第二阴极气体末端导流块20、第一牺牲阳极保护板13、第二牺牲阳极保护板19,所述第一阴极通气柱15、第二阴极通气柱28分别固定于第一阴极定位夹紧座16、第二阴极定位夹紧座5上,所述第一阴极通气接口18、第二阴极通气接口9分别安装于第一阴极通气柱15、第二阴极通气柱28上,所述第一气体换向座14、第二气体换向座4分别固定于第一阴极定位夹紧座16、第二阴极定位夹紧座上5,所述第一阴极气体末端导流块23、第二阴极气体末端导流块20分别固定于第一L型立体曲面阴极25、第二L型立体曲面阴极22上,所述第一牺牲阳极保护板13、第二牺牲阳极保护板19分别固定于第一气体换向座14、第二气体换向座4上,且连接电源正极,作为对相邻叶片29叶身部分的绝缘保护。As shown in Figures 3 and 4, the gas insulation protection assembly includes a first cathode ventilation column 15, a second cathode ventilation column 28, a first cathode ventilation interface 18, a second cathode ventilation interface 9, a first gas reversing seat 14, a second gas reversing seat 4, a first cathode gas terminal guide block 23, a second cathode gas terminal guide block 20, a first sacrificial anode protection plate 13, and a second sacrificial anode protection plate 19. The first cathode ventilation column 15 and the second cathode ventilation column 28 are respectively fixed on the first cathode positioning clamping seat 16 and the second cathode positioning clamping seat 5, and the first cathode ventilation interface 18 and the second cathode ventilation interface 9 are respectively installed on On the first cathode ventilation column 15 and the second cathode ventilation column 28, the first gas reversing seat 14 and the second gas reversing seat 4 are respectively fixed on the first cathode positioning clamping seat 16 and the second cathode positioning clamping seat 5, the first cathode gas end guide block 23 and the second cathode gas end guide block 20 are respectively fixed on the first L-shaped three-dimensional curved cathode 25 and the second L-shaped three-dimensional curved cathode 22, the first sacrificial anode protection plate 13 and the second sacrificial anode protection plate 19 are respectively fixed on the first gas reversing seat 14 and the second gas reversing seat 4, and are connected to the positive pole of the power supply as insulation protection for the blade body part of the adjacent blade 29.
如图4所示,所述第一L型立体阴极曲面25及第二L型立体阴极曲面22的上端面是根据叶盘轮毂30的形状所设计制造,在加工叶片29的同时对叶盘轮毂30进行加工,减少了后续加工步骤,提高了狭窄通道整体叶盘的加工效率。As shown in FIG4 , the upper end surfaces of the first L-shaped three-dimensional cathode curved surface 25 and the second L-shaped three-dimensional cathode curved surface 22 are designed and manufactured according to the shape of the impeller hub 30 . The impeller hub 30 is processed while the blades 29 are processed, which reduces the subsequent processing steps and improves the processing efficiency of the overall impeller of the narrow channel.
如图4所示,所述第一阴极通气柱15、第一阴极通气接口18、第一气体换向座14及第二阴极通气柱28、第二阴极通气接口9、第二气体换向座4组成了两条气绝缘保护流道,在加工过程中向保护流道通入高压气体(图中虚线箭头为气体流通路线),可阻断电解液冲向相邻叶片29叶根部分(图中实线箭头为电解液流通路线),实现对叶片29叶根的气绝缘保护,提高狭窄通道整体叶盘1加工精度。所述第一气体换向座14及第二气体换向座4用于给高压绝缘气体换向的同时,防止了第一阴极定位夹紧座16、第二阴极定位夹紧座5对叶片29的杂散腐蚀。As shown in FIG4 , the first cathode ventilation column 15, the first cathode ventilation interface 18, the first gas reversing seat 14 and the second cathode ventilation column 28, the second cathode ventilation interface 9, and the second gas reversing seat 4 form two gas insulation protection flow channels. During the processing, high-pressure gas is introduced into the protection flow channels (the dotted arrow in the figure is the gas flow route), which can block the electrolyte from rushing to the root part of the adjacent blade 29 (the solid arrow in the figure is the electrolyte flow route), thereby achieving gas insulation protection for the root of the blade 29 and improving the processing accuracy of the narrow channel integral blade disk 1. The first gas reversing seat 14 and the second gas reversing seat 4 are used to reverse the high-voltage insulating gas while preventing the first cathode positioning clamping seat 16 and the second cathode positioning clamping seat 5 from stray corrosion on the blade 29.
本发明还提供了一种气绝缘保护狭窄通道整体叶盘精密电解加工方法,包括以下步骤:The present invention also provides a method for precision electrochemical machining of a gas-insulated narrow channel integral blade disk, comprising the following steps:
(1)将第一快换夹头17、第二快换夹头8分别固定于机床第一主轴26、机床第二主轴27上,之后将第一阴极定位夹紧座16、第二阴极定位夹紧座5分别安装在第一快换夹头17、第二快换夹头8上,随后将第一L型立体曲面阴极25、第二L型立体曲面阴极22分别安装在第一阴极定位夹紧座16、第二阴极定位夹紧座5上,再将第一阴极叶尖处绝缘套24、第二阴极叶尖处绝缘套21分别安装在第一L型立体曲面阴极25、第二L型立体曲面阴极22上,最后将通液柱6安装在第一阴极定位夹紧座16上,将通液接头7接在通液柱6上;(1) The first quick-change chuck 17 and the second quick-change chuck 8 are fixed on the first spindle 26 and the second spindle 27 of the machine tool respectively, and then the first cathode positioning clamping seat 16 and the second cathode positioning clamping seat 5 are installed on the first quick-change chuck 17 and the second quick-change chuck 8 respectively, and then the first L-shaped three-dimensional curved surface cathode 25 and the second L-shaped three-dimensional curved surface cathode 22 are installed on the first cathode positioning clamping seat 16 and the second cathode positioning clamping seat 5 respectively, and then the first cathode blade tip insulating sleeve 24 and the second cathode blade tip insulating sleeve 21 are installed on the first L-shaped three-dimensional curved surface cathode 25 and the second L-shaped three-dimensional curved surface cathode 22 respectively, and finally the liquid column 6 is installed on the first cathode positioning clamping seat 16, and the liquid connection joint 7 is connected to the liquid column 6;
(2)将第一阴极通气柱15、第二阴极通气柱28及第一气体换向座14、第二气体换向座4分别固定于第一阴极定位夹紧座16、第二阴极定位夹紧座5上,之后将第一阴极气体末端导流块23、第二阴极气体末端导流块20分别固定于第一L型立体曲面阴极25、第二L型立体曲面阴极22上,随后将第一牺牲阳极保护板13、第二牺牲阳极保护板19分别固定于第一气体换向座14、第二气体换向座4上,最后将第一阴极通气接口18、第二阴极通气接口9安装在第一阴极通气柱15、第二阴极通气柱28上;(2) The first cathode ventilation column 15, the second cathode ventilation column 28 and the first gas reversing seat 14, the second gas reversing seat 4 are fixed to the first cathode positioning clamping seat 16, the second cathode positioning clamping seat 5, respectively, and then the first cathode gas terminal guide block 23, the second cathode gas terminal guide block 20 are fixed to the first L-shaped three-dimensional curved surface cathode 25, the second L-shaped three-dimensional curved surface cathode 22, respectively, and then the first sacrificial anode protection plate 13, the second sacrificial anode protection plate 19 are fixed to the first gas reversing seat 14, the second gas reversing seat 4, respectively, and finally the first cathode ventilation interface 18, the second cathode ventilation interface 9 are installed on the first cathode ventilation column 15, the second cathode ventilation column 28;
(3)将狭窄通道整体叶盘1安装在叶盘定位柱11上,之后将叶盘后端绝缘盖2安装在叶盘定位柱11上,叶盘夹紧座3固定于叶盘定位柱11上,叶盘前端面绝缘盖2固定于叶盘夹紧座3上,最后将叶盘定位柱11固定于机床竖直主轴10上;(3) Install the narrow channel integral blade disk 1 on the blade disk positioning column 11, then install the blade disk rear end insulation cover 2 on the blade disk positioning column 11, fix the blade disk clamping seat 3 on the blade disk positioning column 11, fix the blade disk front end insulation cover 2 on the blade disk clamping seat 3, and finally fix the blade disk positioning column 11 on the vertical spindle 10 of the machine tool;
(4)启动电解加工机床,启动机床加热系统进行预热,待电解液加工至25~30℃,启动电解液恒温系统;(4) Start the electrolytic machining machine, start the machine heating system for preheating, wait for the electrolyte to reach 25-30°C, and start the electrolyte constant temperature system;
(5)将狭窄通道整体叶盘1与机床正极相连,将第一L型立体曲面阴极25和第二L型立体曲面阴极22与机床负极相连,将第一牺牲阳极保护板13、第二牺牲阳极保护板19与机床正极相连;(5) Connect the narrow channel blisk 1 to the positive electrode of the machine tool, connect the first L-shaped three-dimensional curved cathode 25 and the second L-shaped three-dimensional curved cathode 22 to the negative electrode of the machine tool, and connect the first sacrificial anode protection plate 13 and the second sacrificial anode protection plate 19 to the positive electrode of the machine tool;
(6)操控机床竖直主轴10,使其按照设定好的轨迹移动至待加工的位置,随后进行预通液,检查通液装置密封性,然后停止通液,通入高压气体,检查气绝缘保护组件的密封性,操控机床第一主轴26、机床第二主轴27进行对刀,随后设置电解液参数;(6) Control the vertical spindle 10 of the machine tool to move it to the position to be processed according to the set trajectory, then pre-liquidate, check the sealing of the liquid-passing device, then stop the liquid-passing, pass high-pressure gas, check the sealing of the gas insulation protection component, control the first spindle 26 and the second spindle 27 of the machine tool to calibrate the tool, and then set the electrolyte parameters;
(7)通入电解液及高压气体进行加工,在电化学阳极腐蚀作用下,留有一定余量的狭窄通道整体叶盘1的一个叶片29被加工成所需形状,加工完第一个叶片后停止通液,操控机床竖直主轴10使狭窄通道整体叶盘1离开加工区域,随后操控机床分度轴加工下一个叶片29。(7) Electrolyte and high-pressure gas are introduced for processing. Under the action of electrochemical anode corrosion, a blade 29 of the narrow channel integral blade disk 1 with a certain margin is processed into a desired shape. After the first blade is processed, the liquid flow is stopped, and the vertical spindle 10 of the machine tool is controlled to make the narrow channel integral blade disk 1 leave the processing area, and then the indexing axis of the machine tool is controlled to process the next blade 29.
(8)重复步骤(7)直至加工完狭窄通道整体叶盘1所有叶片29,随后停止通入电解液及高压气体,取出狭窄通道整体叶盘1,关闭机床。(8) Repeat step (7) until all blades 29 of the narrow channel integral blade disk 1 are processed, then stop introducing the electrolyte and high-pressure gas, remove the narrow channel integral blade disk 1, and turn off the machine tool.
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