闭式整体叶盘成组电极高效电弧成形加工技术

贾雨超; 迟关心; 张昆; 张甲; 王振龙

doi:10.7527/S1000-6893.2021.25605

航空学报 >

2022 , Vol. 43 >Issue 4: 525605 - 525605

DOI: https://doi.org/10.7527/S1000-6893.2021.25605

论文

闭式整体叶盘成组电极高效电弧成形加工技术

贾雨超 ,
迟关心 ,
张昆 ,
张甲 ,
王振龙

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1. 哈尔滨工业大学机电工程学院, 哈尔滨 150001;
2. 首都航天机械有限公司, 北京 100076

收稿日期: 2021-03-30

修回日期: 2021-04-12

网络出版日期: 2021-06-01

基金资助

黑龙江省应用技术研究与开发重大项目（GA16A404）

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High-efficiency electrical arc machining of integral shrouded blisk using grouped electrode

JIA Yuchao ,
CHI Guanxin ,
ZHANG Kun ,
ZHANG Jia ,
WANG Zhenlong

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1. School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China;
2. Capital Aerospace Machinery Co., Ltd., Beijing 100076, China

Received date: 2021-03-30

Revised date: 2021-04-12

Online published: 2021-06-01

Supported by

Application of Technology Research and Development Program of Heilongjiang Province (GA16A404)

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摘要

带叶冠的闭式整体叶盘可为液体火箭发动机涡轮泵、航空涡轮发动机等产品提供优异性能，但更高的加工难度也成为制约加工成本和生产能力的瓶颈。目前通常采用电火花加工、电化学加工工艺加工该类开敞性不足的闭式流道，主要问题在于加工效率较低，制造成本昂贵。为此，提出一种使用成组电极在大电流、长脉宽放电条件下进行多流道并行开粗加工的高效电弧加工方法。首先分析了高效电弧放电加工对成组电极设计的要求，提出一种具有内冲液结构的多头成组电极设计方法，然后借助流体仿真工具对电极内部冲液通道的分流结构进行了优化设计。通过试制一款闭式整体叶环，对该方法实际效果进行了验证，测算了加工过程的材料去除率、电极损耗率。结果显示，与此前提出的单头电极电弧加工相比，使用该成组电极后材料去除率提高了62.9%。得益于更高的材料去除率和更少的辅助操作，同款叶盘的开粗用时缩短为常规电火花加工工艺的8.7%。

关键词： 电弧; 放电加工; 电极; 设计; 整体式; 涡轮叶盘; 材料去除率

本文引用格式

贾雨超 , 迟关心 , 张昆 , 张甲 , 王振龙 . 闭式整体叶盘成组电极高效电弧成形加工技术[J]. 航空学报, 2022 , 43(4) : 525605 -525605 . DOI: 10.7527/S1000-6893.2021.25605

Abstract

Integral shrouded blisks provide excellent performance for aviation turbine engines and turbo pumps in liquid rocket engines. However, manufacture of these blisks is much more difficult, making it a bottleneck for the production of engines. Electrochemical machining and electric discharge machining are usually adopted for the machining of these parts. The main drawback is poor machining efficiency, resulting in higher cost. For this reason, an electrical arc machining method that uses a grouped electrode to perform parallel roughing of multiple channels under the conditions of high current and long pulse width discharge is proposed. The requirements for grouped electrode design are discussed based on the principle of arc machining. The design workflow of grouped electrode with internal flushing structure is then proposed. The shunt structure of the internal flushing channel is optimized using computational fluid dynamics simulations. The actual performance of the proposed method is verified by a trial production, and the indicators such as material removal rate and electrode wear rate are analyzed. The results show that compared with the previous electrical arc machining method using singular electrode, the material removal rate using the grouped electrode was increased by 62.9%. The total time consumption was reduced to 8.7% of that of the traditional electric discharge machining, benefited from the increase in material removal rate and the reduction in auxiliary time.

Key words： electric arc; electric discharge machining; electrode; design; integral; turbine blade; material removal rate

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