叶盘流道五轴高效复合放电加工机床及其数控系统设计

Design of Five-axis Hybrid Electrical-discharge Machine Tool and It's NC System for High-efficiency Machining of Turbine Blisk

高速放电铣削加工在航空航天材料加工领域有广阔的应用前景。在叶盘加工中,高速电弧铣削粗加工与电火花成形精加工的结合应用已初步显现出高效率、高精度的潜力,但现有解决方案仍存在工艺衔接困难、集成度低的实际问题。对此,采用模块化思想,设计了使用水基工作介质、集成上述两种加工方法的五轴复合放电加工机床。以Windows电火花数控系统为基础,开发双模式放电加工多轴数控系统,实现了两种加工方式的数据共享和便捷切换。结果表明:该复合加工机床加工TC4钛合金时的平均材料去除率可达到2160 mm^3/min,经过水基介质成形加工后的表面粗糙度Ra<2.7μm,能满足叶盘零件加工需求。

Based on long pulse width and high energy density,High-speed discharge milling has broad application prospects in the field of aerospace material processing.The combination of high-speed discharge roughing and EDM finishing in turbine disk processing has shown the potential for high efficiency and high precision,but the performance of existing solutions is limited by the apparatus.In this regard,a five-axis hybrid electric discharge machine tool was designed with modularity.Two process are integrated on one platform using water-based medium.Based on the Windows EDM CNC system,a dual-mode EDM multi-axis CNC system was developed,providing data sharing and convenient switching between these two processing modes.Experimental verification show the average material removal rate of TC4 titanium alloy is 2160 mm3/min,and surface roughness after sinking EDM using water-based dielectric fluid is Ra2.7μm,fulfilling the requirements of the turbine disk parts machining.