JP7003666B2 - Blisk manufacturing method and holding jig - Google Patents

Description

The present invention relates to a method and a holding jig for manufacturing a blisk by joining a blade to a fan disk by linear friction joining.

The following Patent Document 1 discloses a method of manufacturing a blisk by joining a blade to a fan disk by linear friction welding (LFW). At the time of joining, the fan disk is pressed by the blade, and in that state, the blade is vibrated in a direction perpendicular to the pressing direction. The frictional heat generated on the joint surface at this time welds the disc and the blade.

A disk stub, which is a convex portion having a cross-sectional shape of the blade, is formed in advance at the joint position of the blade of the fan disk. In addition, the blade is pre-integrated with a rectangular parallelepiped collar that is gripped during linear friction joints, and this collar is finally cut and removed by machining (along with burrs at the joints). To. Further, on the fan disk side of the collar, a blade stub, which is a convex portion having a blade cross-sectional shape, corresponding to the above-mentioned disk stub is formed in advance. In LFW, the end face of the disc stub and the end face of the blade stub are frictionally joined.

Japanese Unexamined Patent Publication No. 2012-35325

As disclosed in Patent Document 1, since the blade is vibrated in a state where the fan disk is pressed against the blade during linear friction joining, the blade, particularly the load, acts on the forge load at that time. Deflection occurs in the collar and blade stub. Therefore, in the technique described in Patent Document 1, the amount of deformation of the blade at the time of linear friction joining is predicted, and the joining is performed in anticipation of the predicted deformation. Since the forge load disappears after joining, the deflection of the collar and the like is eliminated, but as a result, the entire blade is deformed and residual stress is generated in the manufactured blisk.

An object of the present invention is to provide a method for manufacturing a blisk and a holding jig capable of suppressing deformation of a blade due to linear friction joining and suppressing residual stress after joining. The term "manufacturing" here includes not only manufacturing but also repair.

The method for manufacturing a brisk of the present invention is a method of linearly friction-bonding the blade and the disc by pressing the disc of the brisk against the blade while reciprocating the blade of the brisk, and holding the blade at the time of linear friction joining. An external force that offsets the deformation caused by the pressing of the disc is applied to the held portion, which is formed integrally with the blade and is cut and removed after the linear friction joining. At the same time, it is characterized in that the blade and the disk are linearly friction-bonded.

The holding jig of the present invention holds the blade in the production of a blisk in which the blade and the disc are linearly frictionally joined by pressing the disc of the blisk against the blade while reciprocating the blade of the blisk. With respect to the pair of first jig and second jig for gripping both ends of the held portion integrally formed on the blade in advance, and the first jig and the second jig. It is characterized by comprising an external force acting mechanism that exerts an external force in the reciprocating direction at a position separated from the held portion in the pressing direction.

The holding jig of the present invention holds the blade in the production of a brisk in which the blade and the disc are linearly frictionally joined by pressing the disc of the brisk against the blade while reciprocating the blade of the brisk. The pair of first jig and second jig for gripping both ends of the held portion integrally formed on the blade in advance, and at least one of the first jig and the second jig. It is characterized by having an external force acting mechanism that applies an external force that becomes a rotational force with the reciprocating direction as the rotation axis.

According to the present invention, it is possible to suppress the deformation of the blade due to the linear friction joining and to manufacture a highly accurate blisk.

It is an overall block diagram of the manufacturing apparatus (provided with a holding jig) used for the manufacturing method which concerns on embodiment. It is a schematic perspective view which shows the blade and a fan disk which are linear friction-bonded by the said manufacturing apparatus. It is a side view which emphasizes the deformation of a blade at the time of joining. It is a rear view of the blade held by the holding jig which concerns on Example 1. FIG. It is a side view of the blade held by the holding jig which concerns on Example 1. FIG. It is a rear view of the blade held by the holding jig which concerns on Example 2. FIG.

FIG. 1 shows a manufacturing device (linear friction joining device) 1 that performs the manufacturing method of the blisk of the present embodiment. The manufacturing device 1 includes a vibration device 2 that reciprocates (vibrates) while holding the blade 10, and a pressing device 3 that presses the fan disk 20 against the blade 10 held by the vibration device 2. The vibration exciter 2 and the pressing device 3 are provided on the base 4. The manufacturing apparatus 1 also includes an external force action mechanism 19 that applies an external force to the blade 10 to be joined at the time of linear friction joining.

The vibrating device 2 reciprocates between a pair of holding jigs 13 including a first jig 11 and a second jig 12 for holding the blade 10 and the pair of holding jigs 13 (blades 10 held by). It is provided with a vibration mechanism 14 for moving (vibrating). The vibration direction (reciprocating direction) of the holding jig 13 is the Y direction (vertical direction) in FIG. The pressing device 3 includes a slide base 15 for holding the fan disk 20 and a pressing mechanism 16 for pushing the slide base 15 to the vibration device 2. When the pressing mechanism 16 pushes the slide table 15 against the vibration device 2, the fan disk 20 held by the slide table 15 is pressed against the blade 10 held by the holding jig 13 of the vibration device 2. The slide (pressing) direction of the slide table 15 is the X direction (horizontal direction) in FIG. The X and Y directions are at right angles to each other.

The pressing device 3 also includes a rotary actuator 17. The rotary actuator 17 rotates the held fan disk 20 to position the position where the blade 10 is joined (disc stub, which will be described later) directly in front of the vibration device 2. The manufacturing device 1 includes a vibration mechanism 14, a pressing mechanism 16, and a control unit 18 that controls a rotary actuator 17. The control unit 18 controls the frequency of the vibration mechanism 14 and the pressing force of the pressing mechanism 16.

An external force action mechanism 19, which will be described in detail later, is also connected to the control unit 18. The external force action mechanism 19 controls a pair of holding jigs 13 (first jig 11 and second jig 12) of the vibration device 2 to apply an external force to the blade 10 held by the holding jig 13. , A bending moment or a twisting moment is generated in the collar 10a. The control unit 18 controls the external force to be applied to control the magnitude of the bending moment and the twisting moment.

Next, the blade 10 and the fan disk 20 to be joined using the above-mentioned manufacturing apparatus 1 will be described with reference to FIG. 2.

A disk stub 20a, which is the base end of the blade at the time of completion, is formed in advance on the outer peripheral surface of the fan disk 20. The fan disk 20 is manufactured by cutting a metal (for example, titanium) that is a material for blisk, and a disc stub 20a is also formed during the cutting process.

On the other hand, the blade 10 basically has a shape obtained by removing the disc stub 20a from the blade at the time of completion, but a rectangular parallelepiped (block-shaped) collar (held portion) 10a for being gripped at the time of joining. Is integrally formed in advance. Therefore, the main body portion 10b of the blade 10 extends from one side surface of the collar 10a, and the blade stub 10c, which is the base end portion of the blade 10, protrudes from the opposite surface of the one side surface. One side surface of the collar 10a on which the main body portion 10b of the collar 10a is extended is hereinafter referred to as a back surface 10ab. The opposite surface (the surface facing the fan disk 20 at the time of joining) from which the blade stub 10c of the collar 10a is projected is hereinafter referred to as a front surface 10af.

The end face of the blade stub 10c is linearly friction-bonded to the end face of the disc stub 20a described above. The blade 10 is also manufactured by cutting a metal (for example, titanium) that is a material for blisk, and a collar 10a is also formed during the cutting process. The collar 10a is finally removed by cutting and is not left in the finished blisk.

The collar 10a is formed to hold the blade 10 firmly in the linear friction joint. If the collar 10a is not provided, a trace of the holding jig will remain on the surface of the blade at the time of completion. Further, if the collar 10a is not provided, the blade 10 cannot be firmly held and vibrated. Further, if the collar 10a is not provided, the pressing load (forge load) of the fan disk 20 to be pressed cannot be firmly received. The size of the collar 10a is determined in consideration of the load acting in the vibration direction at the time of linear friction joining and the forge load described above.

Although it depends on the holding mode of the blade 10 at the time of linear friction joining, the blade 10 at the time of linear friction joining is generally deformed by the forge load F as shown in FIG. In FIG. 3, the deformation is emphasized and shown. When such deformation occurs during linear friction joining, the blade 10 (particularly, the main body portion 10b) after linear friction joining remains deformed so as to fall. In the present embodiment, the collar is used to offset (suppress) such deformation due to the forge load via the holding jig 13 (a pair of the first jig 11 and the second jig 12) of the vibration device 2. An external force is applied to 10a. Then, in a state where the deformation due to the forge load is offset (suppressed) by applying an external force in this way, the holding jig 13 is vibrated to perform joining (manufacturing a blisk).

4 and 5 show the blade 10 held by the holding jig 13 in the case where an external force for generating a bending moment is applied to the collar 10a of the blade 10 via the holding jig 13 (Example 1). The holding jig 13 of this embodiment has the first jig 11 and the first jig 13 in consideration of the holding strength of the blade 10, the workability of attaching the blade 10 to the holding jig 13, the configuration of the external force acting mechanism 19 described above, and the like. It is composed of two jigs 12. The first jig 11 and the second jig 12 can be replaced according to the shape of the blade 10 to be joined. However, since all the blades of the blisk usually have the same shape, it is not necessary to replace the first jig 11 and the second jig 12 when manufacturing a specific blisk.

The first jig 11 holds one end of the collar 10a (upper end in the drawing), that is, one end in the length direction of the collar 10a along the vibration direction of the blade 10 (vertical direction in FIGS. 4 and 5). A bottomed first holding hole 11a is formed on the surface of the first jig 11 that holds one end of the collar 10a. The shape of the first holding hole 11a is substantially equal to the cross-sectional shape of the collar 10a to be held. When holding one end of the collar 10a by the first jig 11, the one end is inserted inside the first holding hole 11a, and the one end surface 10au (upper surface in the figure) of the collar 10a is the bottom surface of the first holding hole 11a. Is in contact with. Since the shape of the first holding hole 11a is substantially equal to the cross-sectional shape of the collar 10a, the outer surface of the collar 10a is also substantially in contact with the inner surface of the first holding hole 11a at one end of the collar 10a.

On the other hand, the second jig 12 holds the other end of the collar 10a (the lower end in the figure) along the vibration direction of the blade 10, that is, the other end of the collar 10a in the length direction. A bottomed second holding hole 12a is formed on the surface of the second jig 12 that holds the other end of the collar 10a. The shape of the second holding hole 12a is also substantially the same as the cross-sectional shape of the collar 10a to be held. When the other end of the collar 10a is held by the second jig 12, the other end is inserted inside the second holding hole 12a, and the other end surface 10al (lower surface in the figure) of the collar 10a is the second holding hole 12a. Is in contact with the bottom of the. Since the shape of the second holding hole 12a is substantially equal to the cross-sectional shape of the collar 10a, the outer surface of the collar 10a is substantially in contact with the inner surface of the second holding hole 12a even at the other end of the collar 10a.

When the blade 10 vibrates, the one end surface 10au is pressed by the first jig 11 (first holding hole 11a), and the other end surface 10al is pressed by the second jig (second holding hole 12a). Therefore, the blade 10 is firmly held along the vibration direction by the holding jig 13 via the collar 10a. On the other hand, the blade 10 receives the forge load as described above, but the above-mentioned external force action mechanism 19 is provided in order to cancel the forge load.

Next, the external force action mechanism 19 will be described. The external force action mechanism 19 of this embodiment applies an external force that causes a bending moment as shown by an arrow in FIG. 5 to the collar 10a. That is, an external force is applied to both ends of the rectangular parallelepiped collar 10a so that both ends of the rectangular parallelepiped collar 10a are tilted toward the main body 10b. The above-mentioned first jig 11 (first holding hole 11a) and second jig (second holding hole 12a) also function as a part of the external force action mechanism 19.

The external force acting mechanism 19 includes an actuator 19a, a deceleration mechanism 19b that amplifies the output (torque) of the actuator 19a, a pair of shafts 19c that are rotated by the torque output from the deceleration mechanism 19b, each shaft 19c, and a first jig 11. It also has an upper screw mechanism 19u constructed between the shafts 19c and a lower screw mechanism 19l constructed between each shaft 19c and the second jig 12. The actuator 19a is a servomotor or the like that is connected to the control unit 18 and is controlled by the control unit 18.

The operating state of the actuator (servo motor) 19a is detected by the control unit 18. Therefore, based on this detection result, the control unit 18 controls the external force acting on the collar 10a. The output of the actuator 19a is input to the deceleration mechanism 19b, and after amplifying the input (torque), it is transmitted to a gear fixed to the upper end of each shaft 19c to rotate each shaft 19c. The pair of shafts 19c are arranged at positions that do not interfere with the main body portion 10b of the blade 10.

The upper screw mechanism 19u constructed on the upper part of each shaft 19c includes a forward male screw 19u1 formed on the outer peripheral surface of the shaft 19c and a forward female screw hole 19u2 formed through the first jig 11. When the shaft 19c is rotated in the forward direction, the first jig 11 is moved downward by the forward male screw 19u1 and the forward female screw hole 19u2. Similarly, the lower screw mechanism 19l constructed at the lower part of each shaft 19c includes a reverse male screw 19l1 formed on the outer peripheral surface of the shaft 19c and a reverse female screw hole 19l2 formed through the second jig 12. Consists of. When the shaft 19c is rotated in the forward direction, the second jig 12 is moved upward by the reverse male screw 19l1 and the reverse female screw hole 19l2.

Here, as shown in FIG. 5, each shaft 19c (center) is separated from the first holding hole 11a and the second holding hole 12a (center) by a distance L in the pressing direction of the fan disk 20. There is. In other words, each shaft 19c (center) is separated from the collar 10a (center) by a distance L in the direction of the forge load. Therefore, when the pair of shafts 19c are rotated forward, a compressive force (external force) in the vibration (reciprocating) direction can be applied at a position separated by a distance L in the pressing direction from the collar (held portion) 10a. Then, by this compressive force, a bending moment as shown by an arrow in FIG. 5 can be generated in the collar 10a whose both ends are held by the pair of first holding holes 11a and the second holding holes 12a.

The amount of movement of the actuator 19a is predetermined so that this bending moment cancels the bending deformation caused by the forge load F. The control unit 18 applies an external force that causes a bending moment to the collar 10a based on the predetermined amount of motion. Since the forge load F and the bending moment that cancels the forge load F act at the time of joining, the deformation of the collar 10a at the time of joining can be suppressed. Since the deformation at the time of joining is suppressed, the residual stress after joining caused by the restoration of the deformation at the time of joining can also be suppressed. In this embodiment, the external force action mechanism 19 also functions as a mechanism for simply clamping the blade 10 (collar 10a) in the vibration direction.

In the above-mentioned Example 1, the deformation as shown in FIG. 3 was suppressed. However, the blade 10 often has a twisted shape (although shown briefly in FIG. 2), and the forge load at the time of joining may cause the collar 10a to be deformed to twist. Such torsional deformation is often caused by a combination with bending deformation as shown in FIG. Torsional deformation may also cause unwanted deformation and residual stress in the blade 10 after joining. In Example 2 described below, a case where an external force that cancels (suppresses) the torsional deformation of the collar 10a is applied will be described. The same or equivalent configurations as those in the first embodiment are designated by the same reference numerals, and their overlapping description will be omitted.

FIG. 6 shows the blade 10 held by the holding jig 13 in the case where an external force for generating a torsional moment is applied to the collar 10a of the blade 10 via the holding jig 13 (Example 2). The first jig 11 of this embodiment is configured to pass through the center of the first holding hole 11a and to be rotatable in a certain direction about a rotation axis parallel to the vibration direction (arrows in FIG. 6). reference). Similarly, the second jig 12 is also configured to be rotatable in the opposite direction with respect to the rotation axis parallel to the vibration direction and passing through the center of the second holding hole 12a (see the arrow in FIG. 6). ). It is not necessary to secure a large rotation angle, and it is sufficient that the required torsional moment can be generated.

The external force action mechanism 19 of this embodiment applies an external force that causes a twisting moment as shown by an arrow in FIG. 6 to the collar 10a. That is, an external force is applied to both ends of the rectangular parallelepiped collar 10a so as to twist the rectangular parallelepiped collar 10a. The first jig 11 (first holding hole 11a) and the second jig (second holding hole 12a) described above also function as a part of the external force action mechanism 19. The external force acting mechanism 19 is based on the actuator 19A such as a servomotor connected to the control unit 18 and controlled by the control unit 18, the deceleration mechanism 19B for amplifying the output (torque) of the actuator 19A, and the torque output from the deceleration mechanism 19B. It also has a rotated shaft 19C, an upper gear mechanism 19U constructed between the shaft 19C and the first jig 11, and a lower gear mechanism 19L constructed between the shaft 19C and the second jig 12. There is. The actuator 19A is connected to the control unit 18, and is a servomotor or the like controlled by the control unit 18.

The operating state of the actuator (servo motor) 19A is detected by the control unit 18. Therefore, based on this detection result, the control unit 18 controls the external force acting on the collar 10a. The output of the actuator 19A is input to the deceleration mechanism 19B, and after the input (torque) is amplified, it is transmitted to a gear fixed to the center of the shaft 19C to rotate the shaft 19C.

The upper gear mechanism 19U constructed on the upper part of the shaft 19C meshes with the gear formed on the side surface of the first jig 11, and when the shaft 19C is rotated in the forward direction, the first jig 11 is shown in the drawing. A rotational force (external force) that rotates in the direction of the arrow can be applied. Similarly, the lower gear mechanism 19L constructed in the lower part of the shaft 19C meshes with the gear formed on the side surface of the second jig 12, and when the shaft 19C is rotated in the forward direction, the second jig 12 Can be applied with a rotational force (external force) that rotates in the direction of the arrow in the figure.

Therefore, when the shaft 19C is rotated forward, that is, the first jig 11 and the second jig 12 are rotated in opposite directions by the forward rotation of the shaft 19C, the upper gear mechanism 19U and the lower gear are rotated. The mechanism 19L is constructed. At the time of joining, the upper end of the collar 10a is held by the first holding hole 11a, and the lower end of the collar 10a is held by the second holding hole 12a. Therefore, a torsional moment can be generated in the collar 10a via the holding jig 13 (a pair of the first jig 11 and the second jig 12) by the rotational force (external force) due to the forward rotation of the shaft 19C. In this embodiment, the rotational force applied to one end (upper end) of the collar 10a by the first jig 11 is loaded in the rotational direction (twisting direction) and the other end (lower end) of the collar 10a is loaded by the second jig 12. The direction of rotation (torsion direction) of the rotational force is opposite to each other.

The amount of movement of the actuator 19A is predetermined so that the torsional moment cancels the torsional deformation caused by the forge load F. The control unit 18 applies an external force that causes a twisting moment to the collar 10a based on the predetermined amount of motion. Since the force for twisting the collar 10a caused by the forge load F and the twisting moment for canceling the twisting moment act at the time of joining, the deformation of the collar 10a at the time of joining can be suppressed. Since the deformation at the time of joining is suppressed, the residual stress after joining caused by the restoration of the deformation at the time of joining can also be suppressed.

In this embodiment, the operating amount of the upper gear mechanism 19U with respect to the rotation of the shaft 19C and the operating amount of the lower gear mechanism 19L with respect to the rotation of the shaft 19C are opposite to each other but are the same. In this way, by applying torsional moments in opposite directions to both ends of the collar 10a, it is possible to generate a large torsional moment while reducing the operable amount of the upper gear mechanism 19U and the lower gear mechanism 19L.

However, one of the first jig 11 and the second jig 12 may be fixed, and the collar 10a may act on an external force that causes a torsional moment only on the other. Further, the operating amount of the upper gear mechanism 19U with respect to the rotation of the shaft 19C and the operating amount of the lower gear mechanism 19L with respect to the rotation of the shaft 19C may be set differently (however, the twisting direction is opposite). By doing so, it may be possible to more effectively cancel (suppress) the torsional deformation mode of the blade 10 at the time of joining.

The present invention is not limited to the above embodiment (Example), and can be appropriately modified within the scope of the invention. For example, the above-mentioned Examples 1 and 2 can be mounted on the manufacturing apparatus 1 at the same time. Since the amount of deformation of the blade 10 (color 10a) due to an external force is not large, it is not always impossible to make the configuration of the first embodiment and the configuration of the second embodiment compatible with each other. Further, for example, three or more shafts 19c in the first embodiment may be provided.

Further, for example, in the first embodiment, the pair of shafts 19c are configured to perform the same operation with each other. However, the pair of shafts 19c (including the upper screw mechanism 19u and the lower screw mechanism 19l) may be symmetrically configured so as to be a mirror image with the position of the blade 10 as the plane of symmetry. That is, in FIG. 4, the upper screw mechanism 19u of the right shaft 19c is a reverse screw, the lower screw mechanism 19l is a forward screw, and the right shaft 19c may always be rotated in the opposite direction to the left shaft. By doing so, the force acting between the shaft 19c on one side (left side) and the first jig 11 and the second jig 12, and the shaft 19c and the first jig 11 and the second jig 12 on the other side (right side). 2 It is possible to offset the force acting on the jig 12.

In addition, FIG. 5 also shows a dotted line showing the shape of the blade after completion inside the collar 10a. When the collar 10a is cut and removed after joining to the fan disk 20, the finished blade has the shape shown by this dotted line.

Further, the manufacturing method and apparatus of the present invention can be used not only for new production of blisk but also for repair of blisk. If some blades of the blisk are damaged (deformed, cracked, etc.), the blades are removed leaving the disc stub 20a. The portion of the disc stub 20a is a base end of the blade and a joint portion with the fan disc 20, and is not easily damaged and can be reused in many cases. The blisk can be repaired by joining a new blade 10 having a collar 10a to the remaining disc stub 20a.

1 Manufacturing equipment (linear friction joining equipment)
2 Vibration device 3 Pressing device 10 Blade 10a Collar (held part)
10b Main body 10c Blade stub (base end)
11 1st jig 11a 1st holding hole 12 2nd jig 12a 2nd holding hole 14 Vibration mechanism 16 Pressing mechanism 19 External force acting mechanism 19a, 19A Actuator 19c, 19C Shaft 19u Upper screw mechanism 19l Lower screw mechanism 19U Upper gear Mechanism 19L Lower gear mechanism

Claims (8)

It is a method of manufacturing a blisk in which the blade and the disc are linearly frictionally joined by pressing the disc of the blisk against the blade while reciprocating the blade of the blisk.
The held portion integrally formed with the blade, which is held at the time of linear friction joining and is cut off after the linear friction joining, receives an external force that cancels the deformation caused by the pressing of the disc on the blade. A method for manufacturing a brisk by linear friction joining, wherein the blade and the disc are linearly frictionally joined while acting on a holding portion. The held portion is formed in a rectangular parallelepiped shape, the main body portion of the blade extends from one side surface of the rectangular parallelepiped, and the base end portion of the blade extends from the opposite surface of the one side surface.
The method for manufacturing a blisk according to claim 1, wherein an external force is applied to both ends of the held portion to generate a bending moment in the held portion so as to tilt the held portion toward the main body. The held portion is formed in a rectangular parallelepiped shape, the main body portion of the blade extends from one side surface of the rectangular parallelepiped, and the base end portion of the blade extends from the opposite surface of the one side surface.
The blisk according to claim 1 or 2, wherein the external force is applied to at least one of both ends of the held portion to generate a twisting moment in the held portion so as to twist the held portion. How to make. The external force is applied to both ends of the held portion, and the twisting direction of the held portion due to the external force applied to one end of the both ends and the held portion due to the external force applied to the other ends of the both ends. The method for producing a blisk according to claim 3, wherein the blisk is twisted in opposite directions to each other. A holding jig that holds the blade in the production of a blisk that linearly friction-bonds the blade and the disc by pressing the disc of the blisk against the blade while reciprocating the blade of the blisk.
A pair of first jigs and second jigs for gripping both ends of the held portion integrally formed on the blade in advance,
The holding control is provided with an external force acting mechanism that exerts an external force in the reciprocating direction on the first jig and the second jig at a position separated from the held portion in the pressing direction. Ingredients. The external force acting mechanism includes a plurality of shafts penetrating the first jig and the second jig, and a screw mechanism formed at both ends of the plurality of shafts. The holding jig according to claim 5. A holding jig that holds the blade in the production of a blisk that linearly friction-bonds the blade and the disc by pressing the disc of the blisk against the blade while reciprocating the blade of the blisk.
A pair of first jigs and second jigs for gripping both ends of the held portion integrally formed on the blade in advance,
A holding jig characterized in that at least one of the first jig and the second jig is provided with an external force acting mechanism that exerts an external force acting as a rotational force with the reciprocating direction as a rotation axis. The external force is applied to both the first jig and the second jig so that the rotation direction of the first jig and the rotation direction of the second jig are opposite to each other. The holding jig according to claim 7, wherein the holding jig is loaded.

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