航空发动机叶片加工过程动态检测实验平台研制

Development of experimental platform for dynamic monitoring of aero-engine blades machining process

航空发动机叶片是前沿制造工艺中极具代表性的零件,具有材料复杂、结构复杂、制造难度大等特点。为探究叶片工件多种加工工艺参数与其加工精度之间的映射关系,设计研制了航空发动机叶片加工过程动态检测实验平台。通过多种传感检测技术方案的综合运用,重点解决了叶片加工过程的三向切削力、工艺系统振动状态、零件结构变形及形位误差等多种参数的动态测量难题,实现了叶片加工过程与工件加工状态的量化表征。实验平台体现了前沿制造技术研究与基础制造工艺教学有机结合的教学改革思路,以叶片的精密加工难题为线索,统筹了涉及难加工材料去除机理与切削动力学理论、数控切削及传感检测技术、薄壁工件的装夹定位技术、加工精度(形位公差与表面完整性等),以及有限元仿真建模工具应用等多方面知识点,让学生在专业课程学习中结合具体的实验操作和数据分析,发现问题、琢磨难点、思考解决方法,进而掌握课程重点知识,同时还能激发学生对先进制造技术的学习热情和学术研究兴趣。

Aero-engine blade is one of the typical parts in advanced manufacturing technology with difficult-to-cut material, complex structure and strict machining requirements. To study the mapping relationship between process parameters and machining accuracy of blades, an experimental platform for dynamic monitoring of aero-engine blade machining process is designed and implemented. The multiple sensors are applied to detect a variety of process parameters, including cutting force, vibration state, structural deformation and geometrical error in the blades machining process. Thus, the quantitative characterization of blade machining process and machining state are obtained by the experimental platform. By clue of the aero-engine blade’s precision machining, the experimental platform combines the advanced research and basic teaching of manufacturing technology, including the removal mechanism of difficult-to-cut material, cutting dynamics theory, CNC machining technology, sensing detection technology, clamping and positioning technology of thin-walled workpiece, machining accuracy(geometric tolerance and surface integrity, etc.), finite element simulation modeling tools and so on. In the teaching practice, students can master the key knowledge of professional courses by experimental operation and data analysis. The experimental platform can also stimulate students’ learning interest in advanced manufacturing technology and related academic research.