整体叶盘通道去余量线切割加工技术研究

Study on Wire Cutting Machining Techniques inRemoving Allowance of Blisk Tunnel

整体叶盘的加工余量主要是在其通道开槽粗加工阶段去除的,合理选取整体叶盘粗加工通道余量去除方法是降低通道加工费用、实现整体叶盘加工经济性的关键。由于线切割机床加工单位成本低的原因,采用线切割加工方法对整体叶盘通道进行去余量加工。提出利用叶型与轮毂偏置面确定通道加工边界;通过比较通道边界投影后的投影面积大小确定最优矢量;然后根据最优矢量确定线切割丝与叶盘端面之间的夹角以及切割区域,实现整体叶盘粗加工阶段去除余量最大化。该方法可以有效地解决整体叶盘粗加工阶段经济性问题。试验表明,线切割加工可以应用在整体叶盘通道去余量加工中,并且与传统数控铣削相比,单个通道的加工费用仅为数控铣削加工费用的1/20。

Machining allowance for a blisk is mainly removed in the rough milling,so selecting the appropriate machining method toremove the allowance of blisk tunnel in the rough milling is key to reducing the tunnel cutting costs and making the blisk machiningeconomically.As the wire cut electrical discharge machining machine processing unit cost is low,wire cutting is used to remove theallowance of tunnel.The processing boundary of tunnel is determined by the offset surface of blade and hub of blisk.The optimalvector is determined by comparing the size of the projected area after the projection of the boundary of the tunnel.Then,the cuttingarea and the angle between the line cutting wire and the end face of the blisk are determined according to the optimal vector,and thecutting area is maximized.This method can effectively solve the economic problems of blisk in the rough milling.The demonstrationshows that the wire cutting can be applied to remove the allowance of blisk,and compared with the traditional CNC milling,theprocessing cost of a single channel is only one-twentieth of the cost of CNC milling.