为了提高整体叶盘通道余量分布的均匀性,提出了电极运动轨迹优化方法。分析了电解加工间隙对电极运动轨迹的影响,优化了工具电极在叶顶及叶根圆柱面上的运动轨迹,并基于轨迹线上采样点作拟合垂线段中点的样条曲线获得新的轨迹线。为了验证优化后轨迹的合理性,进行了叶盘通道电解加工对比试验。试验表明,与优化前的轨迹相比,采用优化后的轨迹,通道型面余量差从4.5 mm减小到2.0 mm,叶片上采样点所对应的叶盆与叶背的余量差从3.5 mm减小到1.2 mm,说明该轨迹优化方法能够均匀通道型面的余量分布,优化了后续精加工工序的加工环境。
In order to improve the distribution uniformity of the channel finishing margin of a blisk channel,an optimization method of the cathode relative to the workpiece is presented. The influence of electrochemical machining (ECM) on cathode movement path is analyzed. The method optimizes the movement paths of the tool cathode on the blade tip and foot cylinder surfaces, and new paths are obtained by fitting the midpoints of vertical lines into the splines based on the sample points of the old paths. Experimental investigations are carried out in order to verify the rationality of the optimized paths. The result reveals that the margin difference of channel surfaces can be decreased to 2.0 mm with the new paths, in contrast to 4.5 mm with the old paths. The margin difference of the concave and convex airfoil surfaces decreases to 1.2 mm from 3.5 mm at the corresponding area of the blade sampling point. It can be concluded that the new paths are well designed and can make the margin distribution of channel surfaces uniform to a certain extent, and the process environment of subsequent finishing is thus optimized.
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