CN113806890A - Verification method for machining process of turbine disc parts - Google Patents
Verification method for machining process of turbine disc parts Download PDFInfo
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Abstract
The invention discloses a verification method for a machining process of a turbine disc part, relates to the field of machining, solves the problem that the optimal machining scheme and machining parameters can be determined only by researching and optimizing a heat treatment mode, a machining process, a process route and a used cutter through a large number of physical tests, reduces the test cost, and adopts the specific scheme that: the method comprises the following steps: performing a part material processability verification test, simulating the part processability, comparing the processability simulation data with the test data, and verifying the feasibility of the part material processability simulation scheme; simulating the characteristic processability of the part, and verifying the feasibility of the characteristic processability simulation scheme through a test; modeling is carried out after parts are simplified through processing characteristic reconstruction, the processing process of the parts is simulated, and the processing technology of the parts is optimized according to comparison of the simulation data of the processing process and the technical requirements.
Description
Technical Field
The invention relates to the field of machining, in particular to a verification method of a machining process of a turbine disc part.
Background
The statements herein merely provide background information related to the present disclosure and may not necessarily constitute prior art.
The disc part has a complex structure and a processing technology, the turbine disc is an important part in an aero-engine and belongs to a large typical thin-wall rotating part, the cross section of the turbine disc is provided with an outer rim with a larger diameter, and the turbine disc is thin in thickness, poor in rigidity and easy to deform.
Besides the thin-wall characteristic and the turbine disc, other more and complex machining characteristics exist, including circular arcs, mortises, cavities and the like, wherein the inner cavity is large, the outer cavity is small, the openness is poor, the semi-finishing allowance is large, the structure size is large, the accessibility of a cutter is poor, and the machining deformation is serious; the inner cavity surface has more transfer arcs and is difficult to process; the tongue-and-groove profile is complicated, the position precision requirement is high, and the processing difficulty is great.
And the turbine disc is used as an important hot end part of the aircraft engine, and high requirements are put forward on the material performance of the turbine disc. High temperature alloys with high yield strength, tensile strength and good thermal stability are often selected to operate reliably and stably in high temperature environments. However, the high temperature alloy has very poor machinability, low machining efficiency and unstable machining quality.
In actual production, high requirements are put forward on the integrity of the machined surface of an important working part of a turbine disk part, but the overall structure of the turbine disk part is complex in shape and poor in rigidity, and the turbine disk part is very easy to deform in machining and affects the integrity of the machined surface. Particularly for the processing of the narrow inner cavity surface of the turbine disc, the turning processing technology is generally adopted in the industry at present, a forming cutter is designed for processing, and the part is deformed due to large cutting force in the processing process; when the formed cutter turns the transfer arc, vibration lines are easy to generate, and the problems that the formed transfer arc is poor in consistency, the arc is unqualified in size and the like are caused.
The inventor finds that in the prior art, in order to obtain the required integrity of the processed surface, a large number of repeated cutting tests are required to research and optimize the heat treatment mode, the processing technology, the process route, the used cutter and the like of the workpiece, determine the optimal processing scheme and processing parameters, and ensure the quality requirement of the product. However, the turbine disc belongs to a large-scale complex part, the material and processing cost of the turbine disc are high, the experiment of directly using a real turbine disc blank is not practical, and the experiment cost is extremely high.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide the verification method for the machining process of the turbine disc part, which can greatly save the material and the machining cost for the test, does not occupy the machine tool equipment on the production field, can be repeatedly used for the integrity test of the machining surface of the typical characteristic in the turbine disc, greatly reduces the test cost, is beneficial to increasing the number of samples for the test, and can more reliably evaluate the integrity of the machining surface of the typical characteristic of the turbine disc.
In order to achieve the purpose, the invention is realized by the following technical scheme:
the invention provides a verification method of a machining process of a turbine disc part, which comprises the following steps:
performing a part material processability verification test, simulating the part processability, comparing the processability simulation data with the test data, and verifying the feasibility of the part material processability simulation scheme;
simulating the characteristic processability of the part, and verifying the feasibility of the characteristic processability simulation scheme through a test;
modeling is carried out after parts are simplified through processing characteristic reconstruction, the processing process of the parts is simulated, and the processing technology of the parts is optimized according to comparison of the simulation data of the processing process and the technical requirements.
As a further technical scheme, the process of the part material machinability verification test is as follows:
determining the type of a material processability verification test and an index for evaluating the surface integrity of the part; and constructing a test piece, and performing a material processability verification test.
As a further technical scheme, the material machinability verification test types comprise a turning test, a milling test and a drilling test.
As a further technical scheme, in the process of a material machinability verification test, the sizes of residual stress, work hardening and surface roughness values under different cutting quantities are measured through an orthogonal test, and the influence degree of the cutting quantities on the residual stress, the work hardening and the surface roughness is obtained by adopting a range analysis method, so that the optimal cutting parameters are obtained.
As a further technical scheme, the process of simulating the characteristic machinability of the part is as follows:
establishing a three-dimensional model for simulating the characteristic machinability, simulating the three-dimensional model, and acquiring cutting force, cutting temperature, machined surface roughness, machined surface microhardness, machined surface layer structure, machined surface residual stress, machined surface grain distribution and orientation, tool wear and service life in characteristic machining.
As a further technical scheme, the part characteristic machinability test comprises a turning test and a milling test, wherein the part is clamped through a lathe fixture during the turning test, and the part is clamped through a 3R fixture during the milling test.
As a further technical scheme, the flange of the lathe fixture is provided with a plurality of flange through holes, and the middle part of the lathe fixture is provided with a cylinder structure.
As a further technical scheme, during a milling test, the 3R clamp is connected with the dynamometer through a cushion block, and the cushion block is provided with a plurality of countersunk through holes.
As a further technical scheme, in a part characteristic machinability test, the part is subjected to pretreatment machining and simulation verification machining, and then the integrity of the machined surface of the part is detected, so that test data is obtained and compared with part characteristic machinability simulation data.
As a further technical scheme, after the part machining process is simulated, simulation data of the part machining process are obtained, and if the simulation data are different from technical requirements, the machining process and process parameters are optimized.
The beneficial effects of the invention are as follows:
(1) the invention respectively carries out simulation on the verification method of the machining process from three levels of material machinability, characteristic machinability and part machinability, verifies the feasibility of the simulation scheme, optimizes the machining process of the part, and researches in a physical test and simulation comprehensive mode, thereby saving a large amount of materials and machining cost for the test and reducing the test cost.
(2) In the process of verifying the machinability of the material, the machinability and the integrity of the machined surface of the turbine disc material are obtained through a large number of physical tests and a proper amount of simulation verification, and the simulation data is compared with the data obtained through the tests, so that the feasibility of a material machinability simulation scheme is ensured.
(3) In the characteristic machinability verification process, the machining performance and the machined surface integrity of the typical characteristic in the turbine disc part are obtained through more simulation and a small amount of test verification, and the data obtained through the test is compared with the simulation data, so that the feasibility of the characteristic machinability simulation scheme is ensured.
(4) In the characteristic processing verification process, corresponding clamps and cushion blocks are designed, so that the test piece can be fixed on different equipment by using special clamps and cushion blocks according to different characteristic processing requirements, the test piece with simplified processing characteristics can be tested by using general equipment, special equipment does not need to be designed and manufactured, and the test cost is reduced.
(5) In the part machinability verification process, a simulation scheme for researching material machinability and characteristic machinability is synthesized, a simulation scheme for machining an actual turbine disk part is provided through process and characteristic combined reconstruction, simulation data is compared with the technical requirements of the actual turbine disk part, the feasibility of the part machinability simulation scheme is ensured, the machining process of the turbine disk part is preferentially determined through simulation in subsequent actual production, and the machining surface integrity of the typical characteristic of the turbine disk can be reliably evaluated without carrying out a large number of physical tests.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and together with the description serve to explain the invention and not to limit the invention.
FIG. 1 is a schematic flow diagram illustrating a method for verifying a machining process for a turbine disk-like component according to one or more embodiments of the present disclosure;
FIG. 2 is a schematic illustration of a material processability verification flow according to one or more embodiments of the present disclosure;
FIG. 3 is a schematic structural view of a turning test piece log, a milling test piece log, a drilling test piece log, according to one or more embodiments of the present disclosure;
FIG. 4 is a schematic representation of a feature machinability verification process according to one or more embodiments of the present disclosure;
FIG. 5 is a schematic front view of a lathe fixture according to one or more embodiments of the present disclosure;
FIG. 6 is a side view schematic illustration of a lathe fixture according to one or more embodiments of the present disclosure;
FIG. 7 is a schematic diagram of a spacer block configuration according to one or more embodiments of the present invention;
FIG. 8 is a schematic illustration of a part machinability verification process according to one or more embodiments of the present disclosure;
FIG. 9 is a schematic diagram of a turning test piece construction according to one or more embodiments of the present disclosure;
FIG. 10 is a cross-sectional schematic view of a turning test piece according to one or more embodiments of the present disclosure;
FIG. 11 is a schematic diagram of a milling test piece structure according to one or more embodiments of the present disclosure;
FIG. 12 is a schematic illustration of a turning trial turned to a semi-finished part according to one or more embodiments of the present invention;
FIG. 13 is a cross-sectional schematic view of a turning trial turned to a semi-finished part according to one or more embodiments of the present invention;
FIG. 14 is a schematic structural view of a semi-finished part turned to a finished part according to one or more embodiments of the present disclosure;
FIG. 15 is a cross-sectional schematic view of a semi-finished part turned to a finished part in accordance with one or more embodiments of the present disclosure;
in the figure: the mutual spacing or size is exaggerated to show the position of each part, and the schematic diagram is only used for illustration;
1. turning a test piece raw material; 2. milling a test piece raw material; 3. drilling a test piece raw material; 4. cushion blocks; 5. a phi 6mm countersunk through hole; 6. a phi 10mm countersunk through hole; 7. and milling the test piece.
Detailed Description
It is to be understood that the following detailed description is exemplary and is intended to provide further explanation of the invention as claimed. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
As introduced in the background art, in the prior art, the optimal machining scheme and machining parameters can be determined only by researching and optimizing a heat treatment mode, a machining process, a process route and a used cutter through a large number of physical tests.
Example 1
In an exemplary embodiment of the present invention, as shown in fig. 1 to 15, a verification method for a machining process of a turbine disk part is provided, which includes the following steps:
the verification method of the machining process is divided into three levels of material machinability verification, characteristic machinability verification and part machinability verification.
The first level is material machinability verification, the level comprises a large number of physical tests and a proper amount of simulation verification, the machining performance and the machined surface integrity of the turbine disc material are researched, a simulation scheme for researching the material machinability is established, the feasibility of the simulation scheme is verified, the performance evaluation indexes mainly comprise cutting force, cutting temperature and machined surface roughness, machined surface microhardness, machined surface layer structure, machined surface residual stress, machined surface grain distribution and orientation, cutter abrasion, service life and the like in the cutting process, and the whole flow is shown in figure 2.
In the first level, test pieces for verifying the machinability of the material need to be designed and are respectively used for turning, milling and drilling, the test in the level is a basic cutting test and can be completed by using a universal machine tool and a universal clamp.
The specific process of the first level is as follows:
s1-1: determining a test type for verifying the influence of the machining process of the turbine disc on the surface integrity of the material, and determining an index for evaluating the surface integrity;
the machining process comprises heat treatment, turning, milling, drilling and the like, and the surface integrity index is specifically determined according to different processes and different quality requirements.
S1-2: setting dynamic performance parameters of the turbine disc workpiece material, and establishing an constitutive equation of the material.
S1-3: the test pieces for the research of the construction material processing technology are respectively used for turning a test piece raw material 1, milling a test piece raw material 2 and drilling a test piece raw material 3, as shown in fig. 3.
S1-4: carrying out heat treatment and machining orthogonal tests, wherein independent variables are process parameters of different processes, and dependent variables are indexes for evaluating surface integrity;
for example, when the turning performance of a turbine disc material is researched, a cylindrical rod with the diameter of 60mm is selected as a test piece, a turning orthogonal test is carried out on the test piece, the optimal parameters of the turning turbine disc material with different turning dosages are researched, more test data are obtained to be compared with simulation result data, evaluation indexes are selected from residual stress, machining hardening and surface roughness of a machined surface, three factors including cutting speed v, feeding amount f and cutting depth ap are selected according to the turning characteristics, each factor corresponds to 3 levels to be researched, and the turning parameters and the corresponding levels are shown in table 1.
TABLE 1 turning parameters and corresponding levels
When the orthogonal test is carried out, the orthogonal test factor level is shown in table 2, the sizes of the residual stress, the work hardening and the surface roughness value under different cutting quantities are measured through the orthogonal test, the influence degree of the cutting quantities on the residual stress, the work hardening and the surface roughness is explored by adopting a range analysis method, and the optimal cutting parameter is found.
TABLE 2 orthogonal test factor horizon
S1-5: the machining performance of the turbine disc material is simulated, a principle verification card three-dimensional model is established in three-dimensional modeling software, the three-dimensional model is led into finite element simulation software, boundary conditions and initial conditions are set, turning machining simulation is carried out on the turbine disc material, and data such as the residual stress, the machining hardening and the surface roughness of the machined surface are acquired.
S1-6: and comparing the evaluation index data obtained by simulation with the data obtained by the test, and verifying the feasibility of the turbine disc material processing performance simulation scheme.
In the embodiment, the cutting machining principle is researched through simulation and the feasibility of the simulation scheme is verified in the first level, the test data of the machining performance of the turbine disc material is obtained, the reliability of the test data is ensured, and the test material and the machining cost are saved.
The second level in this embodiment is feature machinability verification, because complex parts are made up of various machining features, requiring research on different machining features, the level including more simulation simulations and a small number of trial verifications, researching machinability and machined surface integrity of typical features in turbine disk parts, and verifying the feasibility of a feature machinability simulation scheme.
The typical characteristics comprise internal cavity characteristic turning, transition arc characteristic turning, thin-wall characteristic turning, groove characteristic milling and the like, the performance evaluation indexes also comprise cutting force, cutting temperature and machined surface roughness, machined surface microhardness, machined surface layer structure, machined surface residual stress, machined surface grain distribution and orientation, cutter abrasion, service life and the like in the machining process, and the whole process is shown in figure 4.
The specific process of the second level is as follows:
s2-1: and establishing a three-dimensional model for feature machinability simulation in three-dimensional modeling software, wherein the three-dimensional model comprises a thin-wall feature turning model, a switching arc feature turning model, an inner cavity feature turning model, a groove feature milling model and the like.
S2-2: and (3) introducing the three-dimensional model into finite element simulation software, setting a material constitutive model, boundary conditions, initial conditions, contact conditions and the like, and simulating typical characteristic turning and milling processability in S2-1 to obtain data such as cutting force, cutting temperature, machined surface roughness, machined surface microhardness, machined surface layer structure, machined surface residual stress, machined surface grain distribution and orientation, cutter abrasion, service life and the like in characteristic machining.
S2-3: a test piece for verifying a characteristic machinability simulation scheme is prepared and comprises typical characteristics such as an inner cavity, a switching arc, a thin wall and a groove, wherein the typical characteristics are simplified from the characteristics of actual turbine disk parts, and the test piece is made of a turbine disk material.
The test piece in the layer is formed by simplifying the machining characteristics of actual turbine disc parts, the test piece needs to be specially designed, and correspondingly, a special clamp needs to be designed and manufactured for testing.
For the turning test, a fixture shown in fig. 5-6 is designed to clamp the characteristic processing turning test piece, wherein the flange of the lathe fixture is provided with six flange through holes which correspond to flange countersunk holes of the flange of the turning test piece one by one, the positioning surface is a large end surface, and the fixture comprises a lathe triangular chuck clamping part with the length of 50mm and the diameter of phi 50 mm.
For a milling test, a 3R clamp is used for clamping a characteristic processing milling test piece, the clamp needs to be fixed on a dynamometer due to the fact that cutting force in the milling process needs to be measured, and therefore a cushion block 4 for connecting the clamp and the dynamometer is designed and manufactured, as shown in figure 7, phi 6mm countersunk through holes 5 which are symmetrical left and right and are uniformly arranged are formed in two sides of the cushion block, the cushion block is located and fixed with the dynamometer through hinged hexagon socket head bolts, four phi 6mm countersunk through holes 5 which are uniformly distributed in the circumference are formed in the bottom surface of the cushion block, a phi 10mm countersunk through hole 6 is formed in the center of the circumference, and the cushion block is located and fixed with the clamp through hinged hexagon socket head bolts.
In the embodiment, the characteristics of the inner cavity, the switching arc and the thin wall of the turbine disc are taken as examples, and the turning test piece shown in fig. 9-10 is constructed for carrying out the turning test.
Wherein, the turning test piece includes following characteristics:
(1) and forging a blank piece by using a die forging process for the turning test piece, wherein the material of the workpiece is a turbine disk material.
(2) The turned test piece contained six flange countersunk holes at the flange with a diameter of 6.6mm through which the test piece was secured to a custom made special lathe fixture using 6mm reamed socket head cap bolts, as shown in fig. 5-6.
(3) The turning test piece contained a 60mm phi inner cylindrical surface at the center using wire electrical discharge machining, and the cut 60mm phi outer cylinder was recycled for other turning tests.
Similarly, taking the milling groove characteristic of the turbine disk as an example, the milling test piece 7 shown in fig. 11 is constructed and subjected to a milling test.
Wherein, mill the test piece and include following characteristics:
(1) in order to study the influence of the first-level process on the second-level process and conveniently compare the integrity of the processed surfaces of the first level and the second level, a sufficient sampling length needs to be reserved, and therefore the thickness of a milling test piece needs to be larger than or equal to 15 mm.
(2) The milling test piece needs to reserve enough clamping length of the clamp so as to reduce the processing deformation of the test piece and reduce the processing vibration.
(3) Most of the allowance of the milling test piece is removed by the wire cut electric discharge machining equipment.
S2-4: and carrying out verification tests of the characteristic machinability simulation result, wherein the verification tests comprise turning tests, milling tests and the like, and comprise preprocessing processing and simulation verification processing.
Taking the characteristic of turning the inner cavity of the turbine disk as an example, the preprocessing processing refers to rough processing and semi-finishing the inner cavity surface, and the turning test piece in the S2-3 is turned to the size of a semi-finished workpiece through rough processing and semi-finishing, as shown in FIGS. 12-13.
Wherein, the semi-finishing turning parameters are determined according to the process card or the simulation scheme, the simulation verification processing refers to finish machining of the inner cavity surface, and the semi-finishing workpiece is turned to the size of the finishing workpiece, as shown in fig. 14-15; and the finish machining turning parameters are determined according to the process card and the simulation parameters, and the process parameters of the control simulation and the verification test are the same so as to verify the feasibility of the characteristic machinability simulation scheme.
And detecting the integrity of the machined surface after finish machining to obtain test data, wherein the indexes comprise cutting force, cutting temperature, machined surface roughness, machined surface microhardness, machined surface layer structure, machined surface residual stress, machined surface grain distribution and orientation, cutter abrasion, service life and the like in the machining process.
S2-5: and comparing the data obtained by the test with the evaluation index data obtained by simulation, and verifying the feasibility of the simulation scheme of the typical characteristic machining performance of the turbine disc.
In the second level, the influence of the typical characteristics of the turbine disk part on the integrity of the machined surface is researched in a mode of combining simulation and test, a simulation scheme for researching the characteristic machinability is formulated, the feasibility of the simulation scheme of the characteristic machinability is verified through the test, the test on the integrity of the machined surface of the typical characteristics in the turbine disk can be repeated, the test cost is greatly reduced, the number of samples of the test is increased, and the integrity of the machined surface of the typical characteristics of the turbine disk can be evaluated more reliably.
The third level is the simulation of the machinability of the actual part, and the third level is mainly used for carrying out simulation research on the machinability and the integrity of the machined surface of the actual turbine disk part so as to achieve the purposes of saving cost and predicting in advance.
In the first level and the second level, a turbine disk material machinability simulation scheme and a turbine disk typical characteristic machinability simulation scheme are researched, feasibility verification is carried out, the simulation schemes of the first level and the second level are integrated in the third level, a simulation scheme for machining actual turbine disk parts is provided through process and characteristic combined reconstruction, the flow of the research scheme is shown in fig. 8, and the machining process of the turbine disk parts is preferably established through simulation.
The specific process of the third-level research scheme is as follows:
s3-1: and establishing a three-dimensional model obtained by simplifying actual turbine disk parts through processing characteristic reconstruction in three-dimensional modeling software.
S3-2: and importing the three-dimensional model into finite element simulation software, setting a constitutive model, boundary conditions, initial conditions, contact conditions and the like, simulating the machining process of the turbine disc to obtain required result data, and comparing the result data with technical requirements to achieve the purpose of optimizing the machining process.
In the third level, the simulation scheme verified by the material processability and the characteristic processability is used for simulating the actual part simplified model to obtain data such as cutting force, cutting temperature, processed surface roughness, processed surface microhardness, processed surface layer structure, processed surface residual stress, processed surface grain distribution and orientation, cutter abrasion and service life and the like in the processing of the turbine disc part, and the data are compared with technical requirements to realize the optimization of the processing technology without repeating a large number of cutting tests and reduce the test cost.
It will be appreciated that the specifications are the design parameters for the turbine disc in actual production.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A verification method for a machining process of a turbine disc part is characterized by comprising the following steps:
performing a part material processability verification test, simulating the part processability, comparing the processability simulation data with the test data, and verifying the feasibility of the part material processability simulation scheme;
simulating the characteristic processability of the part, and verifying the feasibility of the characteristic processability simulation scheme through a test;
modeling is carried out after parts are simplified through processing characteristic reconstruction, the processing process of the parts is simulated, and the processing technology of the parts is optimized according to comparison of the simulation data of the processing process and the technical requirements.
2. A verification method for a machining process of a turbine disc part as claimed in claim 1, wherein the verification test procedure for the machinability of the part material is as follows:
determining the type of a material processability verification test and an index for evaluating the surface integrity of the part; and constructing a test piece, and performing a material processability verification test.
3. A verification method for a machining process of a turbine disc part as claimed in claim 2, wherein the material machinability verification test types include turning test, milling test, drilling test.
4. A verification method for a machining process of a turbine disc part as claimed in claim 2, wherein in the verification test for machinability of the material, the residual stress, work hardening and surface roughness values under different cutting quantities are measured by an orthogonal test, and the influence degree of the cutting quantities on the residual stress, the work hardening and the surface roughness is obtained by a range analysis method to obtain the optimal cutting parameters.
5. A verification method for a machining process of a turbine disc part as claimed in claim 1, wherein the process of simulating the characteristic machinability of the part is as follows:
establishing a three-dimensional model for simulating the characteristic machinability, simulating the three-dimensional model, and acquiring cutting force, cutting temperature, machined surface roughness, machined surface microhardness, machined surface layer structure, machined surface residual stress, machined surface grain distribution and orientation, tool wear and service life in characteristic machining.
6. The verification method for the machining process of the turbine disc part as claimed in claim 1, wherein the part characteristic machinability test comprises a turning test and a milling test, the part is clamped through a lathe clamp during the turning test, and the part is clamped through a 3R clamp during the milling test.
7. The verification method for the machining process of the turbine disc part as claimed in claim 6, wherein the flange of the lathe fixture is provided with a plurality of flange through holes, and the middle part of the lathe fixture is provided with a column structure.
8. A verification method for a machining process of a turbine disc part according to claim 6, wherein the 3R clamp is connected to the load cell through a block during the milling test, the block being provided with a plurality of countersunk through holes.
9. A verification method for a process of machining a turbine disc like component as claimed in claim 1 wherein in a test of machinability of a feature of the component, the component is subjected to a pre-treatment machining and a simulation verification machining, and thereafter the integrity of the machined surface of the component is checked to obtain test data and compared with the simulation data of the feature of the component.
10. A verification method for a machining process of a turbine disc-like part according to claim 1, wherein simulation data for the machining process of the part is obtained after the simulation of the machining process of the part, and the machining process and process parameters are optimized if the simulation data is different from the specification.
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