大直径整体叶轮数控电解加工技术研究
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摘要
数控电解加工技术是一种将数控技术和电解技术相结合的新型制造技术,它既有数控加工的柔性,又具有一般电解加工的优点,它通过利用简单形状的阴极做展成运动,有效的解决难切削材料零件复杂型面的加工难题。该技术通过多年的研究和试验,日趋成熟。本文在前期研究及应用成果的基础上,以数控电解加工大直径整体叶轮叶间通道及叶片精加工为研究对象,进行了工艺试验研究。
本文以数控电解加工大直径整体叶轮叶间通道、精加工叶片型面为目标,对给定的叶片型面数据点云,利用双三次B样条(B-Spline)曲面,建造整体叶轮三维几何模型。同时以此为基础,讨论了阴极设计、工件偏心装夹时各轴运动量的计算及数控电解加工程序编制;并且对由阴极加工刃边宽度、叶片型面扭曲而导致的过切进行了讨论并提出了解决方案。利用设计的阴极进行了脉冲电流电解加工与直流电解加工试验,对试验中出现的亮斑问题进行了讨论,同时根据试验结果分析,提出利用脉冲电流数控电解加工技术精加工叶片型面。
同时针对阴极设计时流场问题,本文对利用计算流体动力学进行流体流动问题数值计算的主要步骤给以简要说明。对叶间通道加工过程中局部电解液不足、补充电解液后的效果,以及叶片型面加工阴极内部通道对电解液流速的影响等进行了数值模拟,为完善阴极设计提供了流场理论依据,使得加工过程更加稳定可靠。
另外,由于待加工的大直径整体叶轮超出了试验用电解加工机床的运动范围,本文提出利用工件圆心与机床旋转中心不重合的偏心装夹方式予以解决,扩大了小型电解加工机床的加工范围。
最后本文采用偏心装夹方式,针对数控电解加工大直径整体叶轮进行了试验研究,对加工叶间通道、精加工叶片过程中出现的叶根圆过切、型面杂散腐蚀等问题进行了讨论,并提出了相应解决方案;同时对影响加工精度的各种因素予以分析。在此基础上,加工了大直径整体叶轮试件。
Numerical Controlled Electrochemical Machining (NC-ECM) is a new kind of technology which combined the advantages of Electrochemical Machining (ECM) with Numerical Control technology. By using generating motion of simple cathode, this technology can solve the problems in machining complex-shaped components which are made of high-strength and heat-resistant alloys. Through years of research and testing, this technology is becoming mature. Based on the previous relevant researches and literatures, the study took the passage processing and finishing machining of large-diameter integral impeller as the research object, and carried out technological experiments.
To begin with, three-dimensional geometry model of blade was built according to the point cloud data based on Bicubic B-spline Surfaces, thus design of cathode, calculation of the displacements in eccentric clamping, and programming of NC-ECM manufacturing program were studied. Besides, the overcut, which caused by width of cathode’s machining edge and the twist phenomenon of the blade, and its solutions were discussed. Then ECM technological experiments were carried out using DC-power and Pulse power in terms of designed cathode, which contributed to the later discussion the light spots having appeared in DC-power ECM experiments. Accordingly, Pulse power was proposed to be used in machining surfaces of the blade.
Moreover, with reference to flow field of cathode, the steps of numerical simulation are explained on grounds of Computational Fluid Dynamics (CFD). Numerical simulations were carried out to solve the problems caused by local insufficient of electrolyte and the effect of structure of cathode’s inner channel on velocity of electrolyte. These results provided theoretical basis for perfecting the design of cathode.
Furthermore, large-diameter integral impeller waiting to be processed exceeds the machining range of ECM machine, the misalignment between the center of workpiece and rotation centre of ECM machine was put forward to widen the machining range.
Eventually, using this fixturing method, experiments were conducted to perfect NC electrochemical machining large-diameter integral impeller. More importantly, the problems, including the overcut of blade root and dispersion corrosion of blade surface, were discussed and the solution was proposed. The factors affecting machining accuracy were analyzed as well. Based on all these results, the sample of large-diameter integral impeller was machined electrochemically.
本文以数控电解加工大直径整体叶轮叶间通道、精加工叶片型面为目标,对给定的叶片型面数据点云,利用双三次B样条(B-Spline)曲面,建造整体叶轮三维几何模型。同时以此为基础,讨论了阴极设计、工件偏心装夹时各轴运动量的计算及数控电解加工程序编制;并且对由阴极加工刃边宽度、叶片型面扭曲而导致的过切进行了讨论并提出了解决方案。利用设计的阴极进行了脉冲电流电解加工与直流电解加工试验,对试验中出现的亮斑问题进行了讨论,同时根据试验结果分析,提出利用脉冲电流数控电解加工技术精加工叶片型面。
同时针对阴极设计时流场问题,本文对利用计算流体动力学进行流体流动问题数值计算的主要步骤给以简要说明。对叶间通道加工过程中局部电解液不足、补充电解液后的效果,以及叶片型面加工阴极内部通道对电解液流速的影响等进行了数值模拟,为完善阴极设计提供了流场理论依据,使得加工过程更加稳定可靠。
另外,由于待加工的大直径整体叶轮超出了试验用电解加工机床的运动范围,本文提出利用工件圆心与机床旋转中心不重合的偏心装夹方式予以解决,扩大了小型电解加工机床的加工范围。
最后本文采用偏心装夹方式,针对数控电解加工大直径整体叶轮进行了试验研究,对加工叶间通道、精加工叶片过程中出现的叶根圆过切、型面杂散腐蚀等问题进行了讨论,并提出了相应解决方案;同时对影响加工精度的各种因素予以分析。在此基础上,加工了大直径整体叶轮试件。
Numerical Controlled Electrochemical Machining (NC-ECM) is a new kind of technology which combined the advantages of Electrochemical Machining (ECM) with Numerical Control technology. By using generating motion of simple cathode, this technology can solve the problems in machining complex-shaped components which are made of high-strength and heat-resistant alloys. Through years of research and testing, this technology is becoming mature. Based on the previous relevant researches and literatures, the study took the passage processing and finishing machining of large-diameter integral impeller as the research object, and carried out technological experiments.
To begin with, three-dimensional geometry model of blade was built according to the point cloud data based on Bicubic B-spline Surfaces, thus design of cathode, calculation of the displacements in eccentric clamping, and programming of NC-ECM manufacturing program were studied. Besides, the overcut, which caused by width of cathode’s machining edge and the twist phenomenon of the blade, and its solutions were discussed. Then ECM technological experiments were carried out using DC-power and Pulse power in terms of designed cathode, which contributed to the later discussion the light spots having appeared in DC-power ECM experiments. Accordingly, Pulse power was proposed to be used in machining surfaces of the blade.
Moreover, with reference to flow field of cathode, the steps of numerical simulation are explained on grounds of Computational Fluid Dynamics (CFD). Numerical simulations were carried out to solve the problems caused by local insufficient of electrolyte and the effect of structure of cathode’s inner channel on velocity of electrolyte. These results provided theoretical basis for perfecting the design of cathode.
Furthermore, large-diameter integral impeller waiting to be processed exceeds the machining range of ECM machine, the misalignment between the center of workpiece and rotation centre of ECM machine was put forward to widen the machining range.
Eventually, using this fixturing method, experiments were conducted to perfect NC electrochemical machining large-diameter integral impeller. More importantly, the problems, including the overcut of blade root and dispersion corrosion of blade surface, were discussed and the solution was proposed. The factors affecting machining accuracy were analyzed as well. Based on all these results, the sample of large-diameter integral impeller was machined electrochemically.
引文
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