LU101448B1 - Intracavity Variable Tool Cathode for Electrochemical Machining of Blisk with Large-Twisted Blade - Google Patents

Intracavity Variable Tool Cathode for Electrochemical Machining of Blisk with Large-Twisted Blade Download PDF

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Publication number
LU101448B1
LU101448B1 LU101448A LU101448A LU101448B1 LU 101448 B1 LU101448 B1 LU 101448B1 LU 101448 A LU101448 A LU 101448A LU 101448 A LU101448 A LU 101448A LU 101448 B1 LU101448 B1 LU 101448B1
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LU
Luxembourg
Prior art keywords
cathode
connecting rod
intracavity
machining
blisk
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Application number
LU101448A
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French (fr)
Inventor
Lunye Sun
Hao Chen
Hui Wang
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Univ Anhui Sci & Technology
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Publication of LU101448B1 publication Critical patent/LU101448B1/en

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23HWORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H3/00Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
    • B23H3/04Electrodes specially adapted therefor or their manufacture
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23HWORKING 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
    • B23H11/00Auxiliary apparatus or details, not otherwise provided for
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23HWORKING OF METAL BY THE ACTION OF A HIGH CONCENTRATION OF ELECTRIC CURRENT ON A WORKPIECE USING AN ELECTRODE WHICH TAKES THE PLACE OF A TOOL; SUCH WORKING COMBINED WITH OTHER FORMS OF WORKING OF METAL
    • B23H3/00Electrochemical machining, i.e. removing metal by passing current between an electrode and a workpiece in the presence of an electrolyte
    • B23H3/10Supply or regeneration of working media
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23HWORKING 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
    • B23H9/00Machining specially adapted for treating particular metal objects or for obtaining special effects or results on metal objects
    • B23H9/10Working turbine blades or nozzles

Abstract

The invention discloses an intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade, belonging to the technical field of electrochemical machining of blisks. The intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade is characterized in that the cathode structure is formed by combining multiple connecting rods into a cross-sectional shape at the bottom of a blade, and part of the section is provided with retractable connecting rods which are installed in a cathode casing fixed on a cathode fixture; multiple rotatable bases are arranged on both sides of the cathode fixture and provided with electric push rods; and the probes at the tail end of the electric push rods are arranged at the joints of the cathode connecting rods. During machining, the tool cathode, the cathode casing and the internal cathode connecting rod are driven by the fixture drive shaft for synchronously rotating and feeding; while the electric push rod drives the cathode connecting rod to move and change the shape of the intracavity of the cathode. The invention solves the problem that the blisks with section-variable and large-twisted blades cannot be machined by traditional methods such as nesting electrochemical machining, radial forming electrochemical machining and NC-electrochemical contour evolution machining.

Description

Intracavity Variable Tool Cathode for Electrochemical Machining of Blisk withLU101448 Large-Twisted Blade Field of the Invention The invention relates to a structural design of a cathode device for electrochemical machining of a blisk with a section-variable and large-twisted blade, belonging to the technical field of electrochemical machining of blisks.
Background of the Invention Today, aerospace technology is one of the important indicators for weighing a country's scientific and technological level and comprehensive national strength.
How to realize efficient production of high-quality blisk, as the core component of an aero-engine, has become the key technology for aero-engine development.
Ever-increasing thrust-to-weight ratio of aero-engine moves blisk materials toward high strength, high hardness and high temperature resistance such as titanium alloy, making the processing of blisks a major problem in the manufacturing industry.
Electrochemical machining has unique advantages compared with traditional numerical control milling, including high machining efficiency, no tool loss and residual stress, and no consideration given to mechanical properties of materials, which make it one of the key machining methods for blisks.
China has paid more and more attention to the research and development of aviation engines with the development of aviation industry.
In recent years, many research institutions have studied the electrochemical machining process of blisks from a distinctive perspective, and have made certain achievements.
For example, the uniform-section blisk can be machined by the nesting electrochemical machining method, which features an annular tool cathode, and simple structure and high machining efficiency.
The cascade channels are pre-machined by radial forming electrochemical machining method as a common method for electrochemical machining of blisks at present.
In particular, Chinese Patent 200910025834.7 published by Zhu Di et al. on July 21, 2010 proposes a multi-electrode spiral feeding integral impeller blade flow channel electrochemical machining method, which allows the simultaneous machining of the cascade channels of the blisk by multiple tool cathodes placed on the same plane and installed on an electrochemical machining fixture, thus greatly improving the machining efficiency.
Another example is to machine a | 30 developable ruled blade of a bladed disk by combining the linear blade tool cathode and numerical control machine tool. This method is suitable for the profile of the developable ruled blade. LU101448 The nesting electrochemical machining, radial forming electrochemical machining and NC-electrochemical contour evolution machining have their own characteristics and limitations. The casing electrochemical machining can be only used to machine the uniform-section blades with uniform sections. The radial forming electrochemical machining belongs to the pre-machining of cascade channels, and the movement mode of cathode is single radial feeding or spiral feeding, which may cause uneven distribution of blade finishing allowance for a blisk with a large-twisteddistortion blade, and even make it impossible to machine the blade. As the movement path of tool cathode is a developable ruled surface, the NC-electrochemical contour evolution machining method cannot be used to machine a blade of a bladed disk with a twisted and complicated profile. In order to solve the problem that the existing electrochemical machining technology is difficult to machine a blisk with a large-twisted and section-variable blade, it is imperative to study a new cathode device and an electrochemical machining method.
Summary of the Invention The purpose of the invention is to solve the above problems and to provide an intracavity variable tool cathode for electrochemical machining of blisk with large-twisted blade.
In order to achieve the purpose, the invention is embodied by the following technical solutions: introducing a 3D model of a blisk into CAD software; cutting the blades equidistantly and extracting the contour lines of each section by parallel cutting; selecting the contour line of the maximum cross section at the bottom of the blade and stretching at certain offset to obtain an entity, which is divided into multiple connecting rods according to its structural characteristics; and | contracting some of the connecting rods; assembling the connecting rods for the movement simulation; setting the movement mode and the step length of each connecting rod according to the outer contour of the target blade, and reserving the machining allowance; wherein the movement path of the intracavity of cathode connecting rod is the outer contour of the blade profile; and finally, extracting the movement path of the connecting part of each connecting rod. In consideration of the fact that a blisk with a section-variable and large-twisted blade cannot be machined by traditional methods such as nesting electrochemical machining, radial forming electrochemical machining and NC-electrochemical contour evolution machining, the invention | provides an intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade, which is such structured as to realize the variable shape of the intracavity of the | ALL.
cathode during the machining, so that the machined blade profile is close to the target blade profile | j4 01448 to the greatest extent, the reserved leveling allowance can be effectively reduced and the allowance is distributed more uniformly.
The intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade according to the invention consists of a cathode fixture, a cathode casing and a cathode connecting rod, the upper part of the cathode fixture is connected to a fixture drive shaft, the fixture drive shaft is rotatably connected to the cathode fixture, an electrolyte inlet and a rotatable base slot are arranged on both sides of the cathode fixture, multiple rotatable bases are arranged inside the rotatable base slot and provided with an electric push rod, and a probe at the front end of the electric push rod is fixedly connected at the joint of each cathode connecting rod.
A cathode support seat is arranged on both sides of the bottom of the cathode fixture respectively and the upper part thereof is a cathode casing fixedly connected to the cathode support seat, the cathode casing consists of a cathode cover plate and a cathode bottom plate, and the bottom surface of the cathode bottom plate is an arc curved surface.
A slide chute is arranged inside the cathode cover plate and functions as a slide way of a rotating slide connected to the cathode cover plate through a pin, a first retractable connecting rod is fixed on the cathode bottom plate and connected to a first contracted connecting rod, and the first retractable connecting rod, the first contracted connecting rod, a second retractable connecting rod, a second contracted connecting rod, a third retractable connecting rod and a third contracted connecting rod are sequentially connected end to end.
Multiple cathode connecting rods are sequentially connected end to end and are rotatable relative to one another to form a desired blade section profile, and the first contracted connecting rod, the second contracted connecting rod and the third contracted connecting rod are respectively retracted into the first retractable connecting rod, the second retractable connecting rod and the third retractable connecting rod.
Each of the multiple cathode connecting rods is designed into an integral structure comprising a linkage piece outside the connecting rod, the linkage piece outside the connecting rod and the cathode bottom plate can ensure complete removal of material in the cascade channel during machining, and the linkage piece outside the adjacent connecting rods is vertically staggered.
The cathode bottom plate, a bottom surface and an intracavity surface of multiple cathode connecting rods, and a bottom surface of the linkage piece outside the connecting rod are | | | simultaneously machined as a machining face. LU101448 One end of the rotating slide is connected to the cathode cover plate through a pin, and the other end thereof is disposed in the slide chute, and the rotating slide is allowed to rotate around the pin and to be contracted into the slide chute of the cathode cover.
Four electrolyte nozzles are provided in an intracavity of the cathode cover plate, the electrolyte flows into the cathode cover plate from an electrolyte inlet through a cathode support seat, and is respectively supplied to the four electrolyte nozzles through an electrolyte flow channel formed in the cathode cover plate, the electrolyte is sprayed from the nozzle and flows to the machining bottom surface through the machining surface of the intracavity, and finally flows out from both sides of the blade.
The cathode fixture, the cathode casing and each cathode connecting rod are fixedly connected and synchronously fed in during machining.
The beneficial effects of the invention are as follows: the invention provides an intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade, which is such structured as to realize the variable shape of the intracavity of the cathode during the machining, so that the machined blade profile is close to the target blade profile to the greatest extent, the reserved leveling allowance can be effectively reduced and the allowance is distributed more uniformly.
In the machining process, the tool cathode is synchronously rotating and feeding by rotating the drive shaft, while the intracavity of the cathode has gradually changeable shape. In the above movement mode, the cathode structure can be directly used to machine a single bladed disk with a twisted and section-variable blade with a one-step formed blade profile, uniformly distributed machining allowance and high machining efficiency.
When a single blade profile is machined completely, the tool cathode is retracted to the initial position according to the feeding route. After the blisk is indexed, the cathode machines the next blade in the same movement mode and secondary erosion will not occur to the machined blade.
During machining, as the tool cathode is synchronously fed in by rotating the drive shaft, the rotating slide is gradually contracted into the cathode casing. The movement device can effectively solve the problems of insufficient machining at the top of the channel and over-cutting at the bottom due to the large opening angle of the cascade channel.
The invention provides a widely applied electrochemical machining method for blisks. For different blisk models, the cathode structure is designed according to blade profiles.
The contraction | 101448 mode of cathode connecting rod and the feeding route of tool cathode are set through movement simulation, and the movement path of cathode connecting rod is fitted to the blade profile.
During machining, the electrolyte flows into the cathode cover plate from an electrolyte inlet 5 through a cathode support seat, and is respectively supplied to the four electrolyte nozzles through an electrolyte flow channel formed in the cathode cover plate, and the electrolyte is sprayed from the nozzle and flows to the machining bottom surface through the machining surface of the intracavity, and finally flows out from both sides of the blade.
Brief Description of the Drawings Fig. 1 is a schematic diagram of electrochemical machining of a blade of a blisk; Fig. 2 is a schematic diagram of the overall structure of the tool cathode; Fig. 3 is a top view of electrochemical machining of a blade of a blisk; Fig. 4 is a schematic diagram of a cathode casing and an internal connecting rod; Fig. 5 is a structural diagram of a cathode connecting rod; Fig. 6 is schematic diagram of a cathode connecting rod driven by an electric push rod; Fig. 7 is a contracted structure of a cathode connecting rod; In the figures, the components are designated by numerals as follows: cathode fixture 1, cathode casing 2, cathode connecting rod 3, electric push rod 4, fixture drive shaft 5, blisk 6, rotating slide 7, slide chute 8, pin 9, electrolyte nozzle 10, electrolyte inlet 11, rotatable base slot 12, rotatable base 13, cathode support seat 14, cathode cover plate 21, cathode bottom plate 22, first retractable connecting rod 31, first contracted connecting rod 32, second retractable connecting rod 33, second contracted connecting rod 34, third retractable connecting rod 35, third contracted connecting rod 36, linkage piece 37, probe 41, machined blade 61. Detailed Description of the Preferred Embodiment In order to facilitate understanding of the technical means, embodiments, objectives and beneficial effects of the invention, the invention will be further described in detail in combination with drawings.
As shown in Fig. 1 to Fig. 7, the invention provides an intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade, comprising a cathode fixture 1, a cathode casing 2, a cathode connecting rod 3, an electric push rod 4, a fixture driving shaft 5, a blisk 6 and so on.
One end of the fixture drive shaft 5 is fixedly arranged on the machine tool, and the other end thereof is rotatably connected to the cathode fixture 1. An electrolyte inlet 11 and au+101448 rotatable base slot 12 are arranged on both sides of the cathode fixture 1. The rotatable base slot 12 is internally provided with multiple rotatable bases 13, inside which motors are arranged. The rotatable base 13 is provided with an electric push rod 4, and a probe 41 at the front end of the electric push rod 4 is fixedly connected at the joint of each cathode connecting rod 3. A cathode support seat 14 is arranged on both sides of the bottom of the cathode fixture 1 respectively, the upper part thereof is a cathode casing 2, and the cathode casing 2 is fixedly connected to the cathode support seat 14. The cathode casing 2 consists of a cathode cover plate 21 and a cathode bottom plate 22. During machining, the bladed disk to be machined and the cathode structure are respectively connected to the positive electrode and negative electrode of the power supply. The machine tool allows swivel feeding of the cathode fixture 1 driven by the fixture drive shaft 5; at the same time, the rotatable base 13 and the electric push rod 4 can change the shape of the intracavity of the cathode connecting rod 3 by controlling the movement of the probe 41, wherein the movement path of the probe 41 is the movement path of the joint of the movement simulation connecting rods. When a single blade is machined completely, the cathode is retracted to the initial position. The blisk 6 rotates for a certain angle to machine the next blade in the same step. The device not only can directly machine a single section-variable and twisted blade profile in the above movement mode, but also can effectively reduce the reserved leveling allowance and more uniformly distribute the allowance.
As shown in Fig. 1 to Fig. 7, the invention provides an intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade, wherein four electrolyte nozzles 10 are provided in an intracavity of the cathode cover plate 21. During the machining, the electrolyte flows into the cathode cover plate 21 from an electrolyte inlet 11 through a cathode support seat 14, and is respectively supplied to the four electrolyte nozzles 10 through an electrolyte flow channel formed in the cathode cover plate 21, and the electrolyte is sprayed from the nozzle and flows to the machining bottom surface through the machining surface of the intracavity, and finally flows out from both sides of the blade.
As shown in Fig. 1 to Fig. 7, the invention provides an intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade, wherein one end of the rotating slide 7 is connected to the cathode cover plate 21 through a pin 9, and the other end thereof is disposed in the slide chute 8, and the rotating slide 7 is allowed to rotate around the pin 9 and to be contracted into the slide chute 8 of the cathode cover 21. The movement device can effectively 101445 solve the problems of insufficient machining at the top of the channel and over-cutting at the bottom due to the large opening angle of the cascade channel. As shown in Fig. 1 to Fig. 7, the invention provides an intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade, wherein a first retractable connecting rod 31 is fixed on the cathode bottom plate 22 and connected to a first contracted connecting rod 32, and the first retractable connecting rod 31, the first contracted connecting rod 32, a second retractable connecting rod 33, a second contracted connecting rod 34, a third retractable connecting rod 36 and a third contracted connecting rod 35 are sequentially connected end to end; during machining, the probe 41 is such controlled that the rotatable base 13 and the electric push | rod 4 drive the cathode connecting rod 3 to move according to the simulation path, so as to continuously change the shape of the intracavity of the cathode connecting rod 3 and machine a blisk with a section-variable blade.
It is apparent to those skilled in the art that the invention is not limited to the details of the above exemplary embodiments, and can be implemented in other specific forms without departing from the spirit or basic features of the invention. Therefore, the embodiments should be regarded as exemplary and non-limiting in all respects. The scope of the invention is defined by the appended claims rather than the above description, and thus all changes that fall within the meaning and range of equivalent elements of the claims are intended to be included in the invention. Any reference signs in the claims shall not be regarded as limiting the claims involved.
In addition, it should be understood that although this specification is described in terms of embodiments, not every embodiment includes only one independent technical solution, and this description of the specification is for the sake of clarity only. Those skilled in the art should take the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims (7)

CLAIMS LU101448
1. An intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade, the cathode structure being mainly applied to the field of electrochemical machining of blisks, characterized in that the intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade consists of a cathode fixture (1), a cathode casing (2) and a cathode connecting rod (3); the upper part of the cathode fixture (1) is connected to a fixture drive shaft (5), the fixture drive shaft (5) is rotatably connected to the cathode fixture (1), an electrolyte inlet (11) and a rotatable base slot (12) are arranged on both sides of the cathode fixture (1), multiple rotatable bases (13) are arranged inside the rotatable base slot (12) and provided with an electric push rod (4), and a probe (41) at the front end of the electric push rod (4) is fixedly connected at the joint of each cathode connecting rod (3); a cathode support seat (14) is arranged on both sides of the bottom of the cathode fixture (1) respectively and the upper part thereof is a cathode casing (2) fixedly connected to the cathode support seat (14), the cathode casing (2) consists of a cathode cover plate (21) and a cathode bottom plate (22), and the bottom surface of the cathode bottom plate (22) is an arc curved surface; a slide chute (8) is arranged inside the cathode cover plate (21) and functions as a slide way of a rotating slide (7) connected to the cathode cover plate (21) through a pin (9), a first retractable connecting rod (31) is fixed on the cathode bottom plate (22) and connected to a first contracted connecting rod (32), and the first retractable connecting rod (31), the first contracted connecting rod (32), a second retractable connecting rod (33), a second contracted connecting rod (34), a third retractable connecting rod (36) and a third contracted connecting rod (35) are sequentially connected end to end.
2. The intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade according to Claim 1, characterized in that multiple cathode connecting rods (3) are sequentially connected end to end and are relatively rotatable to form a desired blade section profile, and the first contracted connecting rod (32), the second contracted connecting rod (34) and the third contracted connecting rod (35) are respectively retracted into the first retractable connecting rod (31), the second retractable connecting rod (33) and the third retractable connecting rod (36).
3. The intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade according to Claim 1, characterized in that each of the multiple cathodé U101448 connecting rods (3) is designed into an integral structure comprising a linkage piece (37) outside the connecting rod, the linkage piece (37) outside the connecting rod and the cathode bottom plate (22) can ensure complete removal of material in the cascade channel during machining, and the linkage piece (37) outside the adjacent connecting rods is vertically displaced.
4. The intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade according to Claim 1, characterized in that the cathode bottom plate (22), a bottom surface and an intracavity surface of multiple cathode connecting rods (3), and a bottom surface of the linkage piece (37) outside the connecting rod are simultaneously machined as a machining face.
5. The intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade according to Claim 1, characterized in that one end of the rotating slide (7) is connected to the cathode cover plate (21) through a pin (9), and the other end thereof is disposed in the slide chute (8), and the rotating slide (7) is allowed to rotate around the pin (9) and to be contracted into the slide chute (8) of the cathode cover (21).
6. The intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade according to Claim 1, characterized in that four electrolyte nozzles (10) are provided in an intracavity of the cathode cover plate (21), the electrolyte flows into the cathode cover plate (21) from an electrolyte inlet (11) through a cathode support seat (14), and is respectively supplied to the four electrolyte nozzles (10) through an electrolyte flow channel formed in the cathode cover plate (21), the electrolyte is sprayed from the nozzle and flows to the machining bottom surface through the machining surface of the intracavity, and finally flows out from both sides of the blade.
7. The intracavity variable tool cathode for electrochemical machining of a blisk with a large-twisted blade according to Claim 1, characterized in that the cathode fixture (1), the cathode casing (2) and each cathode connecting rod (3) are fixedly connected and synchronously fed in during machining.
LU101448A 2019-04-23 2019-09-24 Intracavity Variable Tool Cathode for Electrochemical Machining of Blisk with Large-Twisted Blade LU101448B1 (en)

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CN110026630B (en) * 2019-04-23 2020-04-14 安徽理工大学 Inner cavity variable tool cathode for electrochemical machining of large-distortion blade blisk
CN110605445B (en) * 2019-08-16 2020-08-21 南京航空航天大学 Electrochemical machining method for non-uniform-speed double-rotation blisk cascade channel
CN111037014B (en) * 2019-11-22 2021-02-26 南京航空航天大学 Nesting electrochemical machining device and method for inward blades of multistage rectifying stator
CN114654034B (en) 2022-05-06 2023-07-14 南京航空航天大学 Electrolytic machining device and method for leaf disk leaf grid group electrode

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