摘要
航空发动机高压压气机叶片弯扭严重、进排气边小、材料加工难度大、精度要求高,采用常规锻造、辊轧、铣削、电解加工方法极难在高效率、低成本的前提下保证其几何精度和表面质量。而常规多轴联动磨削效率过低,且面临复杂的加工残余应力变形问题。因此,利用反向分段残余应力加工控制方法与研制的矩形阵列磨削机床相结合成功实现了多个型号叶片的多主轴同步磨削加工。其中,利用分段方法实现了工件的局部刚性化,等效减小了本段材料的加工变形,利用反向加工顺序消除了本段微小残余应力变形对其他各段的位置移动和误差放大,解决了柔性体局部材料加工过程定位基准的变位问题,使加工残余应力变形的影响减少至接近于零。所加工出的叶片线轮廓度和面轮廓度分别达到30μm和40μm以内,采用4主轴机床后磨削效率较此前单主轴机床的提高近4倍,该方法可以大幅度降低叶片加工成本,并为采用更多主轴机床矩形阵列加工奠定了基础。
The high-pressure compressor blade of aero-engine possesses compound twisted and bowed surface, smallleading/trailing edge radius, difficult-to-machine material, strict design tolerance. It’s difficult to control the blade precisionand surface quality with conventional forging, rolling, milling, electrochemical machining under the premise of low cost andhigh efficiency. Moreover, the conventional multi-axis CNC grinding suffers low efficiency and complex residual stress deformation.Therefore, this paper implements multi-spindle synchronous high-precision grinding of aero-engine blade with thereverse segmented machining method and rectangular array machine tool. By the rigidity improvement and reverse machiningsequences of each segmenting part, the proposed method can ensure the datum superposition principle in the removement offlexible part local material and control the residual stress deformation perfectly. The line/surface profile error of some typicalblades are fluctuant in the range of 30μm/40μm, the machining efficiency is improved by nearly 4 times. These results can notonly reduce manufacturing costs of areo-engine blade greatly, but also establish the foundation for rectangular array machinetool with more spindles extension.
作者
陈志同
张云
刘瑞松
石竖鲲
姜绍西
李深亮
金秀杰
CHEN Zhitong;ZHANG Yun;LIU Ruisong;SHI Shukun;JIANG Shaoxi;LI Shenliang;JIN Xiujie(School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, China;AECC Shenyang Liming Aero Engine （Group） Co., Ltd., Shenyang 210100, China)
出处
《航空制造技术》
2018年第9期34-39,共6页
Aeronautical Manufacturing Technology
关键词
薄壁叶片
复杂型面
残余应力
磨削工艺
阵列加工
Thin-walled blade
Complex surface
Residual stress
Grinding process
Array grinding
