整体叶盘电解扫掠成形精度分析及误差补偿

Accuracy analysis and error compensation on electrochemical sweep-forming of integral blisk

为了提高叶片电解加工精度,分析了过去电解加工叶片加工误差产生的原因,由此推导出机床运动、加工编程、对刀间隙产生的叶片加工误差的计算公式;利用计算机模拟技术对整体叶盘的加工过程进行数值模拟,获取叶片因电解加工过切产生的加工误差分布,其误差随着叶片的扭转角度增加而增大;在此基础上对叶片的加工工艺进行改进,提出了分步法叶片电解加工工艺,在加工中针对叶背加工误差来源采取了不同的补偿措施.试验结果表明,采用分步法加工及补偿措施对叶背加工精度进行补偿,叶背加工误差被控制在0.1mm内,叶根采取单独加工,消除了叶根过切.分步法加工工艺与误差补偿措施的运用可显著提高叶片的加工精度,满足叶片电解加工工序的精度要求.

In order to improve the electrochemical machining（ECM） accuracy of the blade of integral blisk,the causes resulted in machining errors are analyzed in past adopted processes.The computation formulas of the errors caused by the motion of machine tool,numerical control program and initial gap of cathode are deduced.The computer simulation method is used to simulate the ECM course of the blade and the distribution of error arising from the overcut of ECM is obtained.It is found that the error increases with the twist angel of blade.On these bases,a new machining process of fraction step is proposed.In the process the machining errors of the blade can be effectively compensated by different methods.The experiment shows that the machining tolerance can be controlled within 0.1mm by using fraction step process and error compensation.The blade root is machined individually,thus the over-cutting can be eliminated.The applications of the fraction step process and the compensation measures obviously enhance the ECM accuracy of the blade.The accuracy of the machined blade can meet the need of the ECM procedure.