闭式整体构件组合电加工关键技术研究

Key Technology Research of Combined Electrical Machining of Closed Integral Structure

针对包含众多复杂气流通道且由难切削材料制成的封闭式整体构件这一世界性制造难题,对数控电解/数控电火花组合电加工技术进行研究。以几种典型闭式整体构件试制加工为例,论述其总体工艺方案和主要关键技术,包括基于数字化技术的工装夹具、电极及其运动轨迹的设计、加工过程的计算机仿真、叶间流道加工区域划分、工序间加工余量及工艺参数的合理安排等。结合关键闭式整体构件制造技术攻关,通过工艺试验对加工方案进行验证、改进,并试制加工合格的闭式整体构件,解决能加工的问题,相对于单独采用数控电火花加工可提高加工效率40%以上,且能有效降低电极损耗,随着生产批量增大和数控电解加工工艺试验的深入开展,综合加工效率还有较大提升空间。目前已经在新型航空航天发动机、先进透平机械产品的研制中获得成功应用,促进封闭式整体构件制造技术的发展。

In order to solve the worldwide difficult problem of how to machine closed integral structure made of difficult-to-cut material,a new process of combined electrical machining is put forward and studied,that is an organic combination of numerically controlled electrochemical machining（NC-ECM） and numerically controlled electrical discharge machining（NC-EDM）.As an example of trial processing of several typical closed integral structures,its overall technological scheme and main key technologies are discussed,including the design of auxiliary apparatus,electrode and its moving tracks based on digital technology,the computer simulation of combined electrical machining,the working areas partition of integral structure and the arrangement of technological parameters and machining allowance among the processing procedures.Combined with tackling key manufacturing technology of closed integral structure,the machining scheme is verified and improved through technological experiments,and qualified closed integral structures are machined finally.Then,the machinability problem of typical closed integral structure is solved,and the machining efficiency can be improved by above 40% compared to the use of NC-EDM alone,at the same time,the electrode wear can be reduced effectively.With the increase of production lot and the deepening of technological experiments of NC-ECM,there is ample room for improving overall machining efficiency.The above research achievements have been successfully used in the development of new aero-engines,airspace engines and turbo-machines,thus promoting the development of manufacturing technology of closed integral structure.