EP2240290A1 - Method for producing a component for a heat engine - Google Patents

Method for producing a component for a heat engine

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Publication number
EP2240290A1
EP2240290A1 EP08872454A EP08872454A EP2240290A1 EP 2240290 A1 EP2240290 A1 EP 2240290A1 EP 08872454 A EP08872454 A EP 08872454A EP 08872454 A EP08872454 A EP 08872454A EP 2240290 A1 EP2240290 A1 EP 2240290A1
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EP
European Patent Office
Prior art keywords
component
polishing
erosion
producing
blank
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
EP08872454A
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German (de)
French (fr)
Inventor
Alexander Eitel
Daniel Henseler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MAN Energy Solutions SE
Original Assignee
MAN Diesel and Turbo SE
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Publication date
Application filed by MAN Diesel and Turbo SE filed Critical MAN Diesel and Turbo SE
Publication of EP2240290A1 publication Critical patent/EP2240290A1/en
Withdrawn legal-status Critical Current

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Classifications

    • 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
    • B23H9/00—Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects
    • B23H9/10—Working turbine blades or nozzles
    • 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
    • B23H5/00—Combined machining
    • B23H5/02—Electrical discharge machining combined with electrochemical machining
    • 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
    • B23H5/00—Combined machining
    • B23H5/04—Electrical discharge machining combined with mechanical working
    • 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
    • B23H5/00—Combined machining
    • B23H5/06—Electrochemical machining combined with mechanical working, e.g. grinding or honing
    • 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
    • B23H5/00—Combined machining
    • B23H5/14—Supply or regeneration of working media
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/02—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from one piece

Definitions

  • the invention relates to a method for producing a component for a thermal machine, in particular for producing a component for a turbine, a compressor or an expander, in which a blank of the component processed by eroding at least in sections and the surface produced by erosion by superfinishing is processed further. Furthermore, the invention relates to a component for a thermal machine, which is produced by means of the inventive method.
  • Thermal machines such as turbines, compressors or expander
  • components some of which have very complex shapes, such as turbine blades.
  • erosion is increasingly used, a thermal, erosive manufacturing process for conductive components, in which material is removed by electrical discharge processes between an electrode and the component.
  • complex recesses can be formed by eroding, for example specially shaped grooves, pockets with complex cross-sectional shapes or the like.
  • a disadvantage of the use of erosion is that the eroded surface portions, ie the surface portions at which the spark discharge took place, are covered with fine craters and the surfaces show a pitted structure. Furthermore, in peripheral zones of the component, discharge processes, which are often associated with very high temperatures, lead to microstructural changes in the near-surface layer, whereby this near-surface layer is frequently interspersed with microcracks.
  • This layer is also referred to as “recast layer” (also called recast layer) or “white layer”, wherein the thickness and nature of the recast layer, among other things, the setting parameters, the combination of tools and components, the desired surface roughness and Machine depends.
  • the recast layer on the one hand no longer corresponds to the metallurgical structure of the base material used and thus has deviating properties, it is not desirable in particular in the manufacture of components for thermal machines.
  • the recast layer has a comparatively high average roughness Ra in accordance with DIN EN ISO 3274 or DIN EN ISO 4287. This can be in a range of 3 to 4 microns, which is also undesirable for certain applications of components for thermal machines. For this reason, with thermal engine components, the recast layer has hitherto been removed by manual grinding processes.
  • the object of the invention is to provide a method for producing components for thermal machines, with which components of complex shapes with high quality, in particular with high repeatability and surface quality, can be manufactured.
  • this object is achieved by a method having the features according to claim 1 and, in particular, by the fact that fine machining or after a preceding superfinishing of the eroded surfaces is followed by sliding machining and / or electropolishing.
  • electropolishing is also proposed for removing the recast layers.
  • the recast layer can be completely removed by suitable selection of the electrolyte as well as by selective adjustment of the processing time, the current density and the electrolyte temperature, which can also be processed for the grinding inaccessible surface sections.
  • targeted desired average roughness can be generated on the surface to be polished.
  • the blank is produced for example by conventional methods, in particular by primary or forming such as casting, forging or the like and / or, in particular from forging or round material, prepared by machining processes for the inventive method.
  • the erosion of the surfaces preferably takes place in several stages.
  • the material removal is reduced on the one hand by the multi-stage erosion, on the other hand the influence on the structure of further internal layers is reduced. At the same time, this results in a low average roughness than in a single erosion with a larger material removal, which is advantageous for the subsequent superfinishing steps.
  • the eroded body is placed together with grinding wheels and - preferably - a liquid, in particular water, in a working container, which oscillating for Gleitspanen and / or rotating movement performs.
  • the abrasive particles are guided past the surfaces to be treated, wherein the removal of material takes place.
  • ceramic abrasives are used as the abrasive body, which are mixed with appropriate abrasives.
  • additives are preferably added to the liquid.
  • additives can be added to the additives, which also promote the corrosion protection of the components and / or at the same time have a degreasing effect. If a pickling effect is to be achieved, it is also possible to add acidic additives. In the case of flat components, it is also possible to add mechanical release agents (for example small plastic beads) which prevent the components from adhering to one another.
  • the removal of the recast layer during slip cutting can be additionally increased by the addition of chemicals to produce oxalate and phosphate compounds on the eroded surfaces.
  • oxalate and phosphate coatings are produced in particular at the roughness peaks, which have a significantly lower hardness compared to the abrasives.
  • the material removal during sliding machining can be further increased, while at the same time the average roughness can be further reduced.
  • an additional polishing step can follow the sliding chip. If sliding lubrication is assisted by the addition of chemicals for the production of oxalate and phosphate compounds, the polishing can also take place immediately afterwards in the same working container, with the appropriate choice of polishing liquid.
  • a polishing liquid is preferably added to the working container, which neutralizes the chemicals causing the production of oxalate and phosphate compounds and is inert to the material of the component.
  • a polishing liquid for example, a mixture of phosphate salts and Gleitffentensi- is the.
  • the eroded body is placed, at least with portions of its eroded surfaces, in an electrolyte bath of a material-specific electrode. submerged and switched as an anode. Subsequently, the workpiece is subjected to either constant or pulsed direct current. In particular, the use of pulsed current ensures that the recast layer dissolves particularly well from the eroded surface sections.
  • the electropolishing can also be referred to simply as reverse plating.
  • the material removal and the roughness of the surface can be set by specifying a defined processing time, a certain current density or by specifying a specific electrolyte temperature.
  • the electrolyte used is preferably a mixture of water and inorganic acids. Depending on the material of the component, however, it is also possible to use other inorganic acids as the electrolyte, for example a mixture of phosphoric acid and sulfuric acid. The addition of alcohols is possible.
  • slip chipping and electropolishing can be stated in different orders, for example, first sliding glazings with subsequent electropolishing or vice versa.
  • the sliding machining and / or electropolishing can also take place in several stages, optionally alternately.
  • the component After machining the eroded and treated by Gleitspanen and / or electropolishing surfaces, the component can be subjected to further processing steps, such as machining steps or steps for material or material hardening.
  • the inventive method makes it possible for the first time to manufacture components for thermal machines with high repeatability and precision using erosion.
  • the invention relates to a component for a thermal machine, which is produced by means of the method according to the invention.

Abstract

The invention relates to a method for producing a component for a heat engine, especially for producing a component for a turbine, a compressor or an expander, according to which a blank of the component is machined by erosion at least in sections, and the surface produced by erosion is finished by barrel polishing and/or electropolishing in such a way that the recast layer created by the erosion is completely removed at least in sections. The invention also relates to a component for a heat engine, produced by means of said method.

Description

MAN TURBO AG MAN TURBO AG
Verfahren zur Herstellung eines Bauteiles für eine thermische MaschineMethod for producing a component for a thermal machine
Die Erfindung betrifft ein Verfahren zur Herstellung eines Bauteiles für eine ther- mische Maschine, insbesondere zur Herstellung einer Komponente für eine Turbine, einen Kompressor oder einen Expander, bei dem ein Rohling des Bauteils zumindest abschnittsweise durch Erodieren bearbeitet und die durch Erodieren erzeugte Oberfläche durch Feinstbearbeitung weiterbearbeitet wird. Ferner betrifft die Erfindung ein Bauteil für eine thermische Maschine, das mit Hilfe des erfin- dungsgemäßen Verfahrens hergestellt ist.The invention relates to a method for producing a component for a thermal machine, in particular for producing a component for a turbine, a compressor or an expander, in which a blank of the component processed by eroding at least in sections and the surface produced by erosion by superfinishing is processed further. Furthermore, the invention relates to a component for a thermal machine, which is produced by means of the inventive method.
Thermische Maschinen, wie Turbinen, Kompressoren oder Expander, sind vielfach mit Bauteilen ausgestattet, welche zum Teil sehr komplexe Formen aufweisen, beispielsweise Turbinenschaufeln. Zur Herstellung derartiger Bauteile kommt immer häufiger das Erodieren zum Einsatz, ein thermisches, abtragendes Ferti- gungsverfahren für leitfähige Bauteile, bei dem durch elektrische Entladungsvorgänge zwischen einer Elektrode und dem Bauteil ein Materialabtrag erfolgt. Mit dem Erodieren lassen sich insbesondere komplexe Ausnehmungen ausformen, beispielsweise besonders geformte Nuten, Taschen mit komplexen Querschnittsformen oder ähnliches.Thermal machines, such as turbines, compressors or expander, are often equipped with components, some of which have very complex shapes, such as turbine blades. For the production of such components, erosion is increasingly used, a thermal, erosive manufacturing process for conductive components, in which material is removed by electrical discharge processes between an electrode and the component. In particular, complex recesses can be formed by eroding, for example specially shaped grooves, pockets with complex cross-sectional shapes or the like.
Nachteilig bei der Anwendung des Erodierens ist, dass die erodierten Oberflächenabschnitte, also die Oberflächeabschnitte, an denen die Funkenentladung stattfand, mit feinen Kratern übersät sind und die Oberflächen eine narbige Struktur zeigen. Ferner kommt es in Randzonen des Bauteiles durch die Entladungsvorgänge, die oft mit sehr hohen Temperaturen verbunden sind, zu Gefügeände- rungen in der oberflächennahen Schicht, wobei diese oberflächennahe Schicht häufig noch von Mikrorissen durchsetzt ist. Diese Schicht wird auch als „Recast- Schicht" (auch Recastlayer) oder „weiße Schicht" bezeichnet, wobei die Dicke und Beschaffenheit der Recast-Schicht unter anderem von den Einstellparametern, der Materialpaarung von Werkzeug und Bauteil, der gewünschten Oberflächenrauhig- keit und der Maschine abhängt. Da die Recast-Schicht zum einen nicht mehr dem metallurgischen Aufbau des verwendeten Grundwerkstoffs entspricht und somit abweichende Eigenschaften aufweist, ist sie insbesondere bei der Herstellung von Bauteilen für thermische Maschinen nicht erwünscht. Zum anderen weist die Recast-Schicht eine ver- gleichsweise hohe mittlere Rauheit Ra gemäß DIN EN ISO 3274 oder DIN EN ISO 4287, auf. Diese kann in einem Bereich von 3 bis 4 μm liegen, was bei bestimmten Einsatzzwecken von Bauteilen für thermische Maschinen gleichfalls unerwünscht ist. Aus diesem Grund wird bei Bauteilen für thermische Maschinen die Recast- Schicht bisher durch manuelle Schleifprozesse entfernt.A disadvantage of the use of erosion is that the eroded surface portions, ie the surface portions at which the spark discharge took place, are covered with fine craters and the surfaces show a pitted structure. Furthermore, in peripheral zones of the component, discharge processes, which are often associated with very high temperatures, lead to microstructural changes in the near-surface layer, whereby this near-surface layer is frequently interspersed with microcracks. This layer is also referred to as "recast layer" (also called recast layer) or "white layer", wherein the thickness and nature of the recast layer, among other things, the setting parameters, the combination of tools and components, the desired surface roughness and Machine depends. Since the recast layer on the one hand no longer corresponds to the metallurgical structure of the base material used and thus has deviating properties, it is not desirable in particular in the manufacture of components for thermal machines. On the other hand, the recast layer has a comparatively high average roughness Ra in accordance with DIN EN ISO 3274 or DIN EN ISO 4287. This can be in a range of 3 to 4 microns, which is also undesirable for certain applications of components for thermal machines. For this reason, with thermal engine components, the recast layer has hitherto been removed by manual grinding processes.
Allerdings hat sich in der Vergangenheit gezeigt, dass sich insbesondere bei Bauteilen mit komplexen Formen, wie Komponenten für Turbinen, Kompressoren oder Expandern, die Recast-Schicht an schlecht zugänglichen Stellen nicht, nur unzureichend oder nur mit hohem Aufwand entfernen lässt. Gleichzeitig ist eine für die Serienfertigung notwendige hohe Reproduziergenauigkeit an den Oberflächen häufig nicht gewährleistet.However, it has been shown in the past that, especially in the case of components with complex shapes, such as components for turbines, compressors or expanders, the recast layer in hard-to-reach places can not be removed only with sufficient difficulty or only with great effort. At the same time, a high reproducibility on the surfaces, which is necessary for series production, is often not guaranteed.
Aufgabe der Erfindung ist es, ein Verfahren zur Herstellung von Bauteilen für thermische Maschinen anzugeben, mit dem auch Bauteile komplexer Formen mit hoher Qualität, insbesondere mit hoher Wiederholgenauigkeit und Oberflächengüte, gefertigt werden können.The object of the invention is to provide a method for producing components for thermal machines, with which components of complex shapes with high quality, in particular with high repeatability and surface quality, can be manufactured.
Erfindungsgemäß wird diese Aufgabe durch ein Verfahren mit den Merkmalen nach Anspruch 1 gelöst und insbesondere dadurch, dass zur Feinstbearbeitung oder nach einer vorhergehenden Feinstbearbeitung der erodierten Oberflächen ein Gleitspanen und/oder ein Elektropolieren zum Einsatz kommt.According to the invention, this object is achieved by a method having the features according to claim 1 and, in particular, by the fact that fine machining or after a preceding superfinishing of the eroded surfaces is followed by sliding machining and / or electropolishing.
Wie Versuche der Erfinder gezeigt haben, ist es möglich, auch bei sehr komplexen Formen, die durch Erodieren erzeugt worden sind, die entstandene Recast- Schicht durch Gleitspanen und/oder durch Elektropolieren zu entfernen.As experiments by the inventors have shown, it is possible to remove the resulting recast layer by slide cutting and / or by electropolishing, even in the case of very complex shapes which have been produced by erosion.
Beim Gleitspanen, bei dem vorzugsweise kleine Schleifkörper aus mit Schleifmaterial versetzter Keramik oder mit Schleifmaterial versetztem Kunststoff zum Einsatz kommen, erfolgt verfahrensbedingt nicht nur ein Abschleifen der Oberflächen, sondern gleichzeitig auch ein Läppen bzw. Polieren derselben. Dabei lassen sich durch das Gleitspanen nicht nur die teilweise sehr harten Recast-Schichten wirkungsvoll entfernen. Darüber hinaus können Oberflächen mit mittleren Rauheiten Ra nach DIN EN ISO 3274 oder DIN EN ISO 4287 von bis zu Ra 1 ,0-1 ,6 erreicht werden. Ferner können je nach Größe der gewählten Schleifkörper die Recast- Schichten auch an schwer zugänglichen Stellen beseitigt werden.In the case of sliding cutting, in which preferably small grinding bodies made of ceramic mixed with grinding material or plastic mixed with grinding material are used, not only a grinding of the surfaces takes place due to the process, but at the same time a lapping or polishing the same. Not only the partially very hard recast layers can be effectively removed by gliding. In addition, surfaces with average roughness Ra to DIN EN ISO 3274 or DIN EN ISO 4287 of up to Ra 1, 0-1, 6 can be achieved. Furthermore, depending on the size of the selected abrasive, the recast layers can be eliminated even in hard to reach places.
Alternativ oder ergänzend zum Gleitspanen wird ferner das Elektropolieren zur Beseitigung der Recast-Schichten vorgeschlagen. So kann durch geeignete Auswahl des Elektrolyten sowie durch gezieltes Einstellen der Bearbeitungsdauer, der Stromdichte und der Elektrolyttemperatur nicht nur die Recast-Schicht vollständig entfernt werden, wobei auch hier für das Schleifen unzugängliche Oberflächenabschnitte bearbeitet werden können. Darüber hinaus können gezielt gewünschte mittlere Rauheiten an der zu polierenden Oberfläche erzeugt werden.As an alternative or in addition to sliding machining, electropolishing is also proposed for removing the recast layers. Thus, not only the recast layer can be completely removed by suitable selection of the electrolyte as well as by selective adjustment of the processing time, the current density and the electrolyte temperature, which can also be processed for the grinding inaccessible surface sections. In addition, targeted desired average roughness can be generated on the surface to be polished.
Der Rohling wird beispielsweise durch herkömmliche Verfahren, insbesondere durch Ur- oder Umformen wie Gießen, Schmieden oder dergleichen hergestellt und/oder, insbesondere aus Schmiede- oder Rundmaterial, durch spanabhebende Verfahren für das erfindungsgemäße Verfahren vorbereitet.The blank is produced for example by conventional methods, in particular by primary or forming such as casting, forging or the like and / or, in particular from forging or round material, prepared by machining processes for the inventive method.
Weitere vorteilhafte Weiterbildungen der Erfindung ergeben sich aus der Beschreibung sowie den Unteransprüchen.Further advantageous developments of the invention will become apparent from the description and the dependent claims.
Um bereits beim Erodieren eine möglichst geringe mittlere Rauheit einstellen zu können, erfolgt das Erodieren der Oberflächen bevorzugt in mehreren Stufen. Durch das mehrstufige Erodieren wird zwar einerseits der Materialabtrag vermindert, andererseits jedoch der Einfluss auf das Gefüge weiter innenliegender Schichten verringert. Dabei ergibt sich gleichzeitig eine geringe mittlere Rauheit als bei einem einmaligen Erodieren mit größerem Materialabtrag, was für die sich anschließenden Feinstbearbeitungsschritte von Vorteil ist.In order to be able to set the lowest possible average roughness already during erosion, the erosion of the surfaces preferably takes place in several stages. Although the material removal is reduced on the one hand by the multi-stage erosion, on the other hand the influence on the structure of further internal layers is reduced. At the same time, this results in a low average roughness than in a single erosion with a larger material removal, which is advantageous for the subsequent superfinishing steps.
Zum Gleitspanen wird der erodierte Körper gemeinsam mit Schleifkörpern und - bevorzugt - einer Flüssigkeit, insbesondere Wasser, in einen Arbeitsbehälter gegeben, welcher zum Gleitspanen oszillierende und/oder rotierende Bewegung ausführt. Dabei werden die Schleifkörper an den zu behandelnden Oberflächen vorbeigeführt, wobei der Materialabtrag erfolgt. Als Schleifkörper kommen insbesondere keramische Schleifkörper zum Einsatz, welche mit entsprechenden Schleifmitteln versetzt sind. Um den Abtrag weiter zu verbessern und den Ab- transport des Abtrags zu erhöhen, werden der Flüssigkeit vorzugsweise Additive zugesetzt. Dabei können den Additiven zusätzlich Substanzen zugegeben werden, die auch den Korrosionsschutz der Bauteile fördern und/oder gleichzeitig entfettend wirken. Soll eine Beizwirkung erreicht werden, ist auch die Zugabe saurer Additive möglich. Bei flachen Bauteilen können auch mechanische Trennmittel (beispielsweise kleine Kunststoffkügelchen) zugegeben werden, die ein Aneinan- deranhaften der Bauteile verhindern.For Gleitspanen the eroded body is placed together with grinding wheels and - preferably - a liquid, in particular water, in a working container, which oscillating for Gleitspanen and / or rotating movement performs. The abrasive particles are guided past the surfaces to be treated, wherein the removal of material takes place. In particular ceramic abrasives are used as the abrasive body, which are mixed with appropriate abrasives. In order to further improve the removal and to increase the removal of the removal, additives are preferably added to the liquid. In addition, additives can be added to the additives, which also promote the corrosion protection of the components and / or at the same time have a degreasing effect. If a pickling effect is to be achieved, it is also possible to add acidic additives. In the case of flat components, it is also possible to add mechanical release agents (for example small plastic beads) which prevent the components from adhering to one another.
Der Abtrag der Recast-Schicht beim Gleitspanen kann zusätzlich durch die Zugabe von Chemikalien zur Erzeugung von Oxalat- und Phosphatverbindungen an den erodierten Oberflächen erhöht werden. Durch Zugabe derartiger Chemikalien werden insbesondere an den Rauhigkeitsspitzen Oxalat- und Phosphatüberzüge erzeugt, welche im Vergleich zu den Schleifmitteln eine deutlich geringere Härte aufweisen. Dadurch lässt sich der Materialabtrag beim Gleitspanen weiter erhöhen, während gleichzeitig die mittlere Rauheit weiter vermindert werden kann.The removal of the recast layer during slip cutting can be additionally increased by the addition of chemicals to produce oxalate and phosphate compounds on the eroded surfaces. By adding such chemicals oxalate and phosphate coatings are produced in particular at the roughness peaks, which have a significantly lower hardness compared to the abrasives. As a result, the material removal during sliding machining can be further increased, while at the same time the average roughness can be further reduced.
Bei einer besonders bevorzugten Verfahrensführung kann sich an das Gleitspa- nen ein zusätzlicher Polierschritt anschließen. Wird das Gleitspanen durch die Zugabe von Chemikalien zur Erzeugung von Oxalat- und Phosphatverbindungen unterstützt, kann das Polieren bei entsprechender Wahl der Polierflüssigkeit auch unmittelbar anschließend in demselben Arbeitsbehälter erfolgen. Dabei wird in den Arbeitsbehälter vorzugsweise eine Polierflüssigkeit gegeben, welche die die Er- zeugung von Oxalat- und Phosphatverbindungen bewirkenden Chemikalien neutralisiert und dem Werkstoff des Bauteiles gegenüber inert ist. Als Polierflüssigkeit eignet sich beispielsweise ein Gemisch aus Phosphatsalzen und Gleitmitteltensi- den.In a particularly preferred process control, an additional polishing step can follow the sliding chip. If sliding lubrication is assisted by the addition of chemicals for the production of oxalate and phosphate compounds, the polishing can also take place immediately afterwards in the same working container, with the appropriate choice of polishing liquid. In this case, a polishing liquid is preferably added to the working container, which neutralizes the chemicals causing the production of oxalate and phosphate compounds and is inert to the material of the component. As a polishing liquid, for example, a mixture of phosphate salts and Gleitmitteltensi- is the.
Zum Elektropolieren wird der erodierte Körper zumindest mit Abschnitten seiner erodierten Oberflächen in ein Elektrolytbad aus einem werkstoffspezifischen Elekt- rolyten eingetaucht und als Anode geschaltet. Anschließend wird das Werkstück entweder mit konstantem oder gepulstem Gleichstrom beaufschlagt. Insbesondere durch den Einsatz gepulsten Stromes wird erreicht, dass sich die Recast- Schicht von den erodierten Oberflächenabschnitten besonders gut löst. Das Elektropolie- ren kann vereinfacht auch als umgekehrtes Galvanisieren bezeichnet werden. Ferner kann durch Vorgeben einer definierten Bearbeitungsdauer, einer bestimmten Stromdichte oder auch durch Vorgeben einer bestimmten Elektrolyttemperatur gezielt der Materialabtrag und die Rauheit der Oberfläche eingestellt werden.For electropolishing, the eroded body is placed, at least with portions of its eroded surfaces, in an electrolyte bath of a material-specific electrode. submerged and switched as an anode. Subsequently, the workpiece is subjected to either constant or pulsed direct current. In particular, the use of pulsed current ensures that the recast layer dissolves particularly well from the eroded surface sections. The electropolishing can also be referred to simply as reverse plating. Furthermore, the material removal and the roughness of the surface can be set by specifying a defined processing time, a certain current density or by specifying a specific electrolyte temperature.
Als Elektrolyt wird vorzugsweise ein Gemisch aus Wasser und anorganischen Säuren verwendet. In Abhängigkeit von dem Werkstoff des Bauteiles können jedoch auch andere anorganischer Säuren als Elektrolyt zum Einsatz kommen, beispielsweise ein Gemische aus Phosphorsäure und Schwefelsäure. Auch die Zugabe von Alkoholen ist möglich.The electrolyte used is preferably a mixture of water and inorganic acids. Depending on the material of the component, however, it is also possible to use other inorganic acids as the electrolyte, for example a mixture of phosphoric acid and sulfuric acid. The addition of alcohols is possible.
Die Schritte des Gleitspanens und des Elektropolierens können in unterschiedli- chen Reihenfolgen angeführt werden, beispielsweise zunächst Gleitspanen mit anschließendem Elektropolieren oder umgekehrt. Das Gleitspanen und/oder Elekt- ropolieren kann auch mehrstufig, gegebenenfalls abwechselnd, erfolgen.The steps of slip chipping and electropolishing can be stated in different orders, for example, first sliding glazings with subsequent electropolishing or vice versa. The sliding machining and / or electropolishing can also take place in several stages, optionally alternately.
Nach der Bearbeitung der erodierten und durch Gleitspanen und/oder Elektropolieren behandelten Oberflächen kann das Bauteil weiteren Bearbeitungsschritten, wie spanenden Bearbeitungsschritten oder Schritten zur Materialvergütung oder Materialhärtung, unterzogen werden.After machining the eroded and treated by Gleitspanen and / or electropolishing surfaces, the component can be subjected to further processing steps, such as machining steps or steps for material or material hardening.
Durch das erfindungsgemäße Verfahren ist es erstmals möglich, Bauteile für thermische Maschinen mit hoher Wiederholgenauigkeit und Präzision unter Einsatz des Erodierens zu fertigen.The inventive method makes it possible for the first time to manufacture components for thermal machines with high repeatability and precision using erosion.
Ferner betrifft die Erfindung ein Bauteil für eine thermische Maschine, das mit Hilfe des erfindungsgemäßen Verfahrens hergestellt ist. Furthermore, the invention relates to a component for a thermal machine, which is produced by means of the method according to the invention.

Claims

Patentansprüche claims
1. Verfahren zur Herstellung eines Bauteiles einer thermischen Maschine, ins- besondere zur Herstellung einer Komponente für eine Turbine, einen Kompressor oder Expander, bei dem ein Rohling des Bauteils zumindest abschnittsweise durch Erodieren bearbeitet und die durch Erodieren erzeugte Oberfläche durch Gleitspanen und/oder durch Elektropolieren derart bearbeitet wird, dass eine durch das Erodieren entstandene Recast- Schicht zumindest abschnittsweise wenigstens teilweise, insbesondere im Wesentlichen vollständig entfernt wird.1. A method for producing a component of a thermal machine, in particular for producing a component for a turbine, a compressor or expander, wherein a blank of the component machined by eroding at least in sections and the surface generated by erosion by Gleitspanen and / or by Electropolishing is processed in such a way that a recast layer formed by the erosion is at least partially at least partially, in particular substantially completely removed.
2. Verfahren nach Anspruch 1, bei dem das Erodieren in mehreren Stufendurchgeführt wird.2. The method of claim 1, wherein the eroding is performed in multiple stages.
3. Verfahren nach Anspruch 1 oder 2, bei dem der Rohling zum Gleitspanen gemeinsam mit Schleifkörpern und einer Flüssigkeit, insbesondere Wasser, welche vorzugsweise mit einem Additiv versetzt ist, in einen Arbeitsbehälter gegeben wird, welcher zum Gleitspanen oszillierende und/oder rotierende Bewegung ausführt.3. The method of claim 1 or 2, wherein the blank for Gleitspanen together with grinding wheels and a liquid, in particular water, which is preferably mixed with an additive, is placed in a working container, which performs the Gleitspanen oscillating and / or rotating movement.
4. Verfahren nach Anspruch 3, bei dem das Gleitspanen durch Zugabe von Chemikalien zur Erzeugung von Oxalat- und Phosphatverbindungen an den erodierten Oberflächen unterstützt wird.4. The method of claim 3, wherein the slip cutting is assisted by the addition of chemicals to produce oxalate and phosphate compounds on the eroded surfaces.
5. Verfahren nach einem der Ansprüche 1 bis 4, bei dem sich an das Gleitspanen ein Polieren anschließt.5. The method according to any one of claims 1 to 4, wherein the polishing followed by a polishing.
6. Verfahren nach Anspruch 4 und 5, bei dem sich an das Gleitspanen ein Po- lieren anschließt, bei dem in den Arbeitsbehälter eine Polierflüssigkeit gegeben wird, welche die die Erzeugung von Oxalat- und Phosphatverbindungen bewirkenden Chemikalien im Wesentlichen neutralisiert und/oder dem Werkstoff des Bauteiles gegenüber inert ist. 6. The method of claim 4, wherein the polishing is followed by polishing in which a polishing liquid is added to the working vessel which substantially neutralizes the chemicals causing the production of oxalate and phosphate compounds and / or the material is inert to the component.
7. Verfahren nach einem der vorhergehenden Ansprüche 1 bis 5, bei dem zum Elektropolieren der erodierte Rohling zumindest mit Abschnitten seiner erodierten Oberflächen in ein Elektrolytbad aus einem, insbesondere werkstoffspezifischen, Elektrolyten eingetaucht und als Anode geschaltet mit konstantem oder gepulstem Gleichstrom beaufschlagt wird.7. The method according to any one of the preceding claims 1 to 5, wherein for electropolishing the eroded blank is immersed at least with portions of its eroded surfaces in an electrolyte bath of a, in particular material-specific, electrolyte and connected as an anode connected to a constant or pulsed direct current.
8. Verfahren nach Anspruch 7, dadurch gekennzeichnet, dass der Elektrolyt ein Gemisch aus einer Flüssigkeit, insbesondere Wasser, und einer oder mehrerer anorganischen Säuren, wie Salzsäure und/oder Schwefelsäure und/oder Salpetersäure, ist.8. The method according to claim 7, characterized in that the electrolyte is a mixture of a liquid, in particular water, and one or more inorganic acids, such as hydrochloric acid and / or sulfuric acid and / or nitric acid.
9. Bauteil für eine thermische Maschine, hergestellt durch ein Verfahren nach einem der vorhergehenden Ansprüche 1 bis 8. 9. A component for a thermal machine, produced by a method according to one of the preceding claims 1 to 8.
EP08872454A 2008-02-13 2008-11-19 Method for producing a component for a heat engine Withdrawn EP2240290A1 (en)

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DE200810008894 DE102008008894A1 (en) 2008-02-13 2008-02-13 Method for producing a component for a thermal machine
PCT/EP2008/009784 WO2009100745A1 (en) 2008-02-13 2008-11-19 Method for producing a component for a heat engine

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