基于非均匀余量的整体叶轮加工工艺优化策略

Machining Process Optimization Strategy of Integral Impeller Based on Non-Uniform Machining Allowance

针对超薄结构叶片整体叶轮在制造过程中叶片产生较大的变形和切削振动,使用非均匀余量加工工艺方案,减小叶片变形提高加工质量。分析了集中载荷对薄壁结构和加厚结构变形的影响,对生产中的叶轮叶片进行非均匀余量加工工艺设计,依据优化后的工艺对叶轮进行刀具轨迹规划并进行加工试验,结果显示该工艺优化策略能有效减小超薄叶片的铣削振动和铣削变形,最大误差优化率为54.47%,平均误差优化率为52.57%,对类似高度与平均厚度比值较大且叶片扭转曲率较大的复杂零件的实际加工有一定的指导意义。

Large deformation and cutting vibration are important problems in the process of manufacturing ultra-thin blade of integral impeller, thus a non-uniform allowance process is used in this paper, which can reduce blade deformation and improve processing quality. Firstly, the influence of concentrated load both on the deformation of thin-walled struc- ture and thickening structure wad was analyzed. Then non-uniform allowance machining process of impeller blade was designed. Lastly, tool path was planned and processing experiment was done on the impeller. Results show that the process optimization strategy can effectively reduce milling vibration and milling deformation of ultra-thin blade, the max error optimization rate is 54.47% and the average error optimization rate is 52.57%, which is of significance to the actual production.