整体叶盘电解加工全过程电流控制方法研究
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摘要
提出了叶盘型面电解加工的全过程电流控制方法,基于电流控制思想,通过全程控制电流这一重要参数,使其在多次加工中基本保持一致,从而提高型面加工的重复精度。开展了电流控制方法的理论分析,掌握了工具进给速度和电流变化的对应关系,形成了加工过程中的电流调控策略,并设计了以电解加工电流为调控目标的实时运动调节系统。针对Ti60整体叶盘开展了一系列对比试验研究,结果表明:采用该电流控制方法可保证多次加工电流的一致性,进而保证加工间隙及型面重复精度。叶盆、叶背受控线重复精度可控制在0.06 mm,有效地保证了每次加工精度的一致性。
The method of the current control is proposed in the whole process of electrochemical machining for blisk profiles. With making the current almost consistent in the multiple-processing,the repeatability of the profile precision will be improved. The theory of the current control method was carried out,and the relationship between the tool feeding rate and the current changing was established.Furthermore,the strategy of the current control was attained and the automatic regulating system of cathode feeding based on the changing current was developed. A series of contrast experiments were carried out for Ti60 titanium alloy blisk. The results show that the consistency of the current in multiple processing was guaranteed with the current control method,leading a good consistency of the machining gap. Finally,the repeated accuracy of the control lines in the basin and back was effectively ensured,and the repeated accuracy could be controlled under 0.06 mm.
The method of the current control is proposed in the whole process of electrochemical machining for blisk profiles. With making the current almost consistent in the multiple-processing,the repeatability of the profile precision will be improved. The theory of the current control method was carried out,and the relationship between the tool feeding rate and the current changing was established.Furthermore,the strategy of the current control was attained and the automatic regulating system of cathode feeding based on the changing current was developed. A series of contrast experiments were carried out for Ti60 titanium alloy blisk. The results show that the consistency of the current in multiple processing was guaranteed with the current control method,leading a good consistency of the machining gap. Finally,the repeated accuracy of the control lines in the basin and back was effectively ensured,and the repeated accuracy could be controlled under 0.06 mm.
引文
[1]徐家文,云乃彰,王建业,等.电化学加工技术[M].北京:国防工业出版社,2008.
[2]史耀耀,段继豪,张军锋,等.整体叶盘制造工艺技术综述[J].航空制造技术,2013(3):26-31.
[3]RAJURKAR K P,Zhu Di,MCGEOUGH J A,et al.New developments in electrochemical machining[J].Annals of CIRP,1999,48(2):567-580.
[4]RISKO D G,DAVYDOV A D.Manufacturing applications and productivity limitations of electrochemical machining[J].Manufacturing Science and Engineering,1993,64:701-711.
[5]徐庆,徐正扬,朱荻,等.整体叶盘通道电解加工电极多维运动轨迹优化[J].航空学报,2011,32(8):1548-1554.
[6]王明海,孙越.整体叶盘叶片铣削加工表面质量控制仿真研究[J].机械设计与制造,2013,4(4):176-182.
[7]钟燕,胡超.线性摩擦焊整体叶盘焊缝结构设计及试验[J].燃气涡轮试验与研究,2012,25(增刊1):44-47.
[8]徐家文,云乃彰,王建业,等.电化学加工技术[M].北京:国防工业出版社,2008.
[9]RAJURKAR K P,SUNDARAM M M,MALSHE A P.Review of electrochemical and electrodischarge machining[J].Procedia CIRP,2013,6(1):13-26.
[10]BUβMANN M,KRAUS J,BAYER E.An integrated cost effective approach to blisk manufacturing[C]//Proceedings of 17th Symposium on Air Breathing Engines.Munich,2005.
[11]朱永伟,徐家文.复合平面摆动展成电解加工整体构件异形面的成形分析及应用[J].机械工程学报,2008,44(12):280-286.
[12]张明歧,傅军英.高温合金整体叶盘精密振动电解加工方法的应用分析[J].航空制造技术,2009(22):26-29.
[13]ZHU Dong,ZHU Di,XU Zhengyang.Optimal design of the sheet cathode using W-shaped electrolyte flow mode in ECM[J].International Journal of Advanced Manufacturing Technology,2012,62(1):147-156.
[2]史耀耀,段继豪,张军锋,等.整体叶盘制造工艺技术综述[J].航空制造技术,2013(3):26-31.
[3]RAJURKAR K P,Zhu Di,MCGEOUGH J A,et al.New developments in electrochemical machining[J].Annals of CIRP,1999,48(2):567-580.
[4]RISKO D G,DAVYDOV A D.Manufacturing applications and productivity limitations of electrochemical machining[J].Manufacturing Science and Engineering,1993,64:701-711.
[5]徐庆,徐正扬,朱荻,等.整体叶盘通道电解加工电极多维运动轨迹优化[J].航空学报,2011,32(8):1548-1554.
[6]王明海,孙越.整体叶盘叶片铣削加工表面质量控制仿真研究[J].机械设计与制造,2013,4(4):176-182.
[7]钟燕,胡超.线性摩擦焊整体叶盘焊缝结构设计及试验[J].燃气涡轮试验与研究,2012,25(增刊1):44-47.
[8]徐家文,云乃彰,王建业,等.电化学加工技术[M].北京:国防工业出版社,2008.
[9]RAJURKAR K P,SUNDARAM M M,MALSHE A P.Review of electrochemical and electrodischarge machining[J].Procedia CIRP,2013,6(1):13-26.
[10]BUβMANN M,KRAUS J,BAYER E.An integrated cost effective approach to blisk manufacturing[C]//Proceedings of 17th Symposium on Air Breathing Engines.Munich,2005.
[11]朱永伟,徐家文.复合平面摆动展成电解加工整体构件异形面的成形分析及应用[J].机械工程学报,2008,44(12):280-286.
[12]张明歧,傅军英.高温合金整体叶盘精密振动电解加工方法的应用分析[J].航空制造技术,2009(22):26-29.
[13]ZHU Dong,ZHU Di,XU Zhengyang.Optimal design of the sheet cathode using W-shaped electrolyte flow mode in ECM[J].International Journal of Advanced Manufacturing Technology,2012,62(1):147-156.