大型水轮机转轮的计算机辅助制造技术(英文)

Computer Aided Manufacturing for Large Hydro Turbine's Runners

转轮是由一系列叶片和回转特征的零件组成。叶片是大型水轮机中最关键和最难制造的部件之一。为了高效制造这类叶片和有效地控制制造成本,研究开发出了一系列的计算机辅助叶片制造技术,包括:基于水轮机叶片制造要求的数字化设计、通过三维数字化测量的计算机辅助定位及误差评估、提高数控加工效率并能有效控制加工误差的刀位轨迹计算策略、通过建立虚拟数控加工叶片的仿真环境来验证数控加工的刀位轨迹和加工过程、以及切实可行并系统化的大型叶片五轴联动数控加工工艺。研究开发的数字化制造技术已成功用于大型轴流式和混流式水轮机叶片制造中,实际表明既可提高加工效率又能获得更好的叶片曲面加工精度。

Hydro turbine's runner consists of blades and rotary parts. Blades are one of the vital components and most difficulty in manufacturing of large hydro turbines. In order to cost-effectively and productively manufacture these kinds of blades, a series of digital techniques in manufacturing have been developed, which includes digital design of hydro turbine blades based on manufacture' requirements, Computer-aided location and the machined error evaluation by using 3-dimensional digitized measuring, tool path generation strategy to meet requirements of enhancing machining efficiency and controlling deviation in NC machining, tool path generation and NC machining simulation by establishing a virtual NC machining environment for blades, and reasonable and feasible strategy and the systematic scheme for manufacturing of large blades by using 5-axis simultaneous CNC machining. The developed computer aided manufacturing techniques have been successfully applied in manufacturing of both the large Kaplan and Francis hydraulic turbine blades, it shows that higher efficiency and the better surfaces finish accuracy can be achieved.