RU2674358C1 - Method of finishing treatment of workpieces of gas turbine engine blade and device for its implementation - Google Patents

Abstract

FIELD: machine building.

SUBSTANCE: invention relates to the field of engineering and can be used for finishing machining of complex spatial forms, in particular gas turbine engine blades (GTE). Workpiece is moved to the treatment area and the geometric parameters of the workpiece are scanned in orthogonal coordinates in the transverse, longitudinal and vertical directions using a measuring module. Obtained data is transmitted to the control unit, in which mathematical data processing is performed, compared with the theoretical form of the part and determining the set of areas for processing the workpiece with the help of a working tool as it moves along three orthogonal coordinates. Carry out the removal of the current parameters of the processing of the workpiece with the help of a torque sensor, which are transmitted to the control unit to generate control commands. At the same time, on the basis of the device, there is a portal installed with a workpiece, a working tool, a measuring unit and actuators for moving the tool and the workpiece, associated with the measuring unit and the control unit.

EFFECT: result is a high-performance finishing surface of GTE blades.

5 cl, 4 dwg, 1 tbl

Description

The invention relates to the field of engineering, including methods and devices for finishing processing of parts of complex spatial shapes, in particular blanks of gas turbine engine blades (GTE).

The blanks for the finish processing of the blades of gas turbine engines are made by forging and stamping, then they are milled. At the same time, restrictive requirements on accuracy to the thickness of the workpiece are satisfied, but the stability of the angle of its twist relative to the longitudinal axis and the given surface curvature are not ensured. Therefore, to obtain a finished blade, adaptive finishing with an abrasive tool is necessary, taking into account the shape of the workpiece and ensuring smooth mates between different types of surfaces. As finishing operations, grinding and polishing are used - grinding to ensure acceptable geometric dimensions, polishing - to obtain the required surface quality; Currently, these operations are performed on different machines.

There is a method for forming a three-dimensional external surface of an object (patent US 8747188 B2, IPC V24V 49/00 from 02.24.2011), which includes creating a 3D model of the object and forming a tool path relative to the part according to this model. The disadvantage of this method is the inability to process each surface of the GTE blade in an optimal way for this surface.

Known 3D printer for the layered manufacturing of volumetric parts, including a base, a print head mounted on a carriage equipped with a module for its movement in the XY plane parallel to the base of the printer; a work table equipped with a device for heating the working surface, mounted at the base and equipped with a movement module along the Z axis; coils located on the base of the printer with mechanisms for supplying consumables to the print head, the device for moving the carriage includes two longitudinal rail and at least one transverse guide, the longitudinal guide is located on the Y axis and rigidly fixed to the base, the transverse guide is located on the axis X between two longitudinal guides with the ability to move along them, and the carriage has the ability to move along the transverse guide by means of drive belts (RF patent and utility model №164639, Cl. B41F 17/00, 2016).

A device for mechanical processing of products of complex spatial shapes, in which grinding is performed by the relative relative movement of the rotational drive of the tool relative to the workpiece (patent RU 2475347 C1, IPC V24V 19/14, V23C 3/18, B25J 9/00 from 08/23/2011) . The disadvantage of this device is the lack of means for measuring the workpiece and, therefore, the inability to adapt the control program to changes in the shape of the workpiece.

There is also a known method of manufacturing parts using forging and further adaptive grinding (patent RU 2550449 C2, IPC B21K 3/04, B24B 19/14, B24B 21/16 from 06/26/2009). After the forging operation, the geometric characteristics of the workpiece are measured and compared with the corresponding dimensions of the theoretical model that sets the geometric characteristics of the finished part. On the surface of the workpiece, zones of inconsistency (mismatch) in dimensions are identified and the amount of material that must be removed in each of these zones is determined to eliminate this discrepancy. The workpiece is sanded with abrasive tape. The amount of material removed is controlled by changing the speed of the part relative to the abrasive belt in the longitudinal direction of the part in accordance with predetermined ratios obtained by calibration.

The disadvantage of this method is the inability to process the surface of the interface of the locking part and the feather of the blade and the lack of non-contact measurement of the dimensions of the workpiece by an optical control system.

The closest technical solution in relation to the proposed set of essential features is the method of finishing processing of the blades of a gas turbine engine and a device for its implementation (RF patent No. 2629419 from 02.25.2016, IPC V24V 19/14). The method includes measuring the geometric characteristics of the blade blank, comparing the measured shape of the blank with the theoretical shape of the finished blade, determining the areas of the blade blank for polishing, shaping the tool path, setting cutting modes for polishing based on the measured data, and performing polishing, characterized in that the geometric parameters of the blank the blades are measured using an optical control system, and the determination of the areas of the workpiece for polishing is carried out by thematic overlay of at least one of the surfaces of the finished blade acceptable by the mathematical model and the measured surface of the workpiece, while for polishing use a tool in the form of a polishing wheel having conical, toroidal and second conical cutting surfaces on it intended for processing sections of the surface of the blade, respectively, the back and trough, the concave surface of the interface of the shelf and the surface of the shelf, and the formation of the trajectory of the tool and the establishment of cutting methods are carried out for the said cutting surfaces of the polishing wheel, moreover, polishing of the mentioned areas in the sections of the blade blank is carried out by the corresponding cutting surfaces of the polishing wheel using two manipulators for the relative movement of the workpiece and the wheel. The device that implements this method contains a measuring module, drives for moving the workpiece of the blade and rotation of the tool for polishing, and also contains a manipulation system with two manipulators for separately moving drives for rotating the tool and moving the workpiece, and the measuring module is made in the form of an optical system for monitoring the geometric characteristics of the workpiece including a numerical control system for said manipulators, wherein a polishing wheel is used as a tool, Making a bevel aligned with toroidal and second bevel cutting surfaces, respectively, intended for the treatment of the backrest and the blade trough, the concave surface of the shelf and its mating surface of the shelf.

The disadvantages of these technical solutions are:

- either the complete absence of the measuring system, or the difficulty of measuring the geometry of the workpiece, including due to the different fixing conditions of the workpiece for measurement, which requires adaptation of the measuring system to each workpiece.

- low productivity of obtaining finished parts due to the need to perform several auxiliary operations - reinstalling blanks.

The advantages of the proposed technical solutions are:

- finishing operations - grinding, polishing, as well as preliminary and final measurements of the workpiece and part are performed in one installation, which ensures reduction of base errors and increases the accuracy of part manufacturing;

- high accuracy of measuring the geometry of the workpiece by linking the location of the measuring module to the carriage and the working tool.

- high performance by reducing the number of technological operations (measurement, reinstallation, etc.)

- the ability to perform finishing operations - and grinding and polishing in one installation;

- the ability to perform measurements (before processing and control measurement after processing) without reinstalling the workpiece-part;

- the ability to choose the installation option of the workpiece (console or with two fixed ends, depending on the rigidity or dimensions of the blade);

- the ability to apply different methods (technologies) for measuring the geometry of the workpieces;

- the ability to control both macrogeometry (dimensions) and microgeometry (surface roughness) for one installation of the part;

- a more rigid design of the machine and the entire AIDS system, allowing the use of increased processing modes (or to provide lower levels of vibration at comparable processing modes);

- the presence of a built-in tool magazine revolving type allows you to process parts with different tools;

- a large service area;

- a simpler control system;

- the presence in the control system of the function of calculating the approximate processing time for synchronizing the supply of the next workpiece to the processing zone;

- the possibility of parallel work with two tools (simultaneous grinding and polishing);

- the presence of a tool magazine and a tool editing unit;

- the ability to use the retractable carriage only to move the part (manual and automatic installation) to accelerate the supply of the workpiece to the processing zone;

- the ability to carry out processing using cutting fluid and without it;

- the availability of the option of embedding the measuring system in the rack of the portal;

- the possibility of using an additional supporting lower support connected to the carriage to increase the rigidity of the blade blank;

- the ability to rotate the part around the Z axis (for a circle);

- the ability to handle the disk with the blades assembly.

The problem to which the claimed invention is directed is to perform a high-performance finishing operation for processing the surfaces of a GTE blade, taking into account the particular geometry of the part.

To achieve this goal, a method for the finish processing of a workpiece of a blade of a gas turbine engine is proposed, including measuring the geometric characteristics of the workpiece, comparing the measured shape of the workpiece with the theoretical shape of the finished part, determining the areas of the workpiece for finishing, shaping the tool path, establishing cutting conditions based on the measured data and finishing processing, while using a working tool in the form of a circle. In the proposed method, the workpiece is moved to the processing zone and the geometric parameters of the workpiece are scanned in the transverse, longitudinal and vertical directions along the Y, X, Z axes using the measuring module by moving it uniformly along the axis of the rotating workpiece, after which the data of the measured shape of the workpiece transmit to the control unit, in which the mathematical processing of the data is carried out, comparing the measured shape of the workpiece with the theoretical shape of the part and determining the set areas for machining the workpiece, on the basis of which the workpiece is processed with the working tool by jointly moving the working tool along the three orthogonal coordinates Y, X, Z, while the current workpiece processing parameters are removed using the torque sensor, which are transmitted to the control unit for generating commands management. During all operations, the working tool is rotated relative to the longitudinal axis of the body X, and the workpiece is rotated relative to its longitudinal axis during machining with the possibility of fixing it in a certain position.

A device is also proposed that implements a new method for finishing a blade of a gas turbine engine, comprising a base on which a portal is mounted with a workpiece, a cutting tool, a measuring unit, and tool and workpiece movement drives connected to the measuring unit and the control unit. The portal is movable relative to the base with the possibility of longitudinal movement along the Y axis and a workpiece feed manipulator, a measuring unit and a transverse movement carriage along the X axis with a housing fixed on it for installing a removable working tool with the possibility of vertical movement of the tool relative to the Z axis are installed on it. an additional torque sensor is installed on the housing, connected with the control unit, which has feedback with the movement drives of the portal, carriage, tool block and the manipulator with the workpiece, and installed on the basis of the workpiece feed manipulator provides the possibility of a fixed position or rotation of the workpiece around the Y axis during processing.

An embodiment of the device according to the scheme with two movable portals is possible, a carriage with a processing tool is installed on one portal, and a workpiece with a workpiece and a measuring module are installed on the other, both portal being based on the same basis.

The proposed method for the finish processing of the blades of a gas turbine engine is carried out in the device described below for processing complex geometric surfaces, including for the finishing processing of a GTE blade, is illustrated by the following illustrations.

In FIG. 1 shows a view of a device for finishing a GTE blade,

in FIG. 2 shows a diagram of the device when feeding the workpiece of the blade in the manipulator,

in FIG. 3 shows a device with a measuring optical module located on the portal,

in FIG. Figure 4 shows a device with two portals - a carriage with a processing tool is installed on one portal, and a measuring module is installed on the other.

On the base 1 there is a portal 2 with the possibility of movement along the Y axis relative to the base 1 using ball screw drives (ballscrews) 3 and stepper motors 4 on linear rail guides (not shown in the figure) (Fig. 1). The carriage 5 is located on the portal 2 with the possibility of moving along the X axis using a ball screw 6 and a stepper motor 7. On the carriage 5 there is a housing 8 with a working tool 9, for example, a grinding or polishing wheel driven by a motor 10. The housing 8 is arranged movement along the Z axis and rotation about this axis with the help of a motor (not shown in the figure). A force-torque sensor (not shown) is also attached to the housing 8 and is connected to the working tool 9. A sensor 5 for measuring the geometrical coordinates 11 of the gasket surface of the GTE blade - part 12 is also located on the carriage 5. A system for measuring the geometrical coordinates of the part - measuring module 11 is installed with the possibility movement along the Z axis relative to the carriage 5. The measuring module 11 can be performed both optical and mechanical. The workpiece of the blade 12 is fixed in the workpiece feed manipulator 13 with the possibility of rotation about the X and Y axis using motors (not shown in the figure). The torque sensor, measuring module 11, motors 4, 7 and the engine of the housing 8 are connected to a control unit (not shown), which processes the information received from the torque sensor and measuring module 11 and generates control commands for moving the working tool.

The device can be made with a measuring optical module with a transmitting and receiving part 11 (Fig. 3) located on the portal 2. The device is equipped with two portals 2 and 14 (Fig. 4) - on the portal 2 there is a carriage 5 with a processing tool 9, and on portal 14 measuring module 15, made, for example, in the form of a probe.

The method and device are implemented as follows.

The workpiece 12 is moved to the device using, for example, a robot (not shown in the figures), then it is placed in the clamping device (not shown in the figure) of the workpiece feed manipulator 13 and rotated 180 degrees (Fig. 2), thereby moving her to the treatment area. The geometric characteristics of the blade blank are measured by an optical or mechanical system for measuring the geometric coordinates of part 11 by moving the measuring module 11 along the Z axis and carriage 5 along the X axis and portal 2 along the Y axis (Fig. 1). It is also possible to contactlessly measure the coordinates of the surface of the part 12 by the measuring module 11 by moving the carriage 5 along the X axis and the portal 2 along the Y axis.

The data of the measured shape of the part 12 is transmitted to the device control unit (not shown), where the measured shape of the workpiece 12 is compared with the theoretical shape of the part and the set of areas for processing this workpiece is determined, as well as the path and cutting conditions for the working tool 9. Then they process the workpiece 12 with a working tool 9 when the body 8, the portal 2 and the carriage 5 are moving. The processing parameters of the workpiece 12 are transferred to the machine control system using a torque sensor for I am developing management teams. If necessary, after processing, the geometrical dimensions of the workpiece are monitored using the measuring module 11. If the required manufacturing accuracy is achieved, the control unit sends the workpiece 12 for further technological operations, otherwise, for reprocessing.

The method is also implemented using a measuring optical module 11, which is fastened to the portal 2 (Fig. 3). The measuring optical module 11 consists of a receiving and radiating part, for example a laser emitter and a line of photocells. The portal 2 moves relative to the workpiece 12 and the measuring optical module 11 scans the geometric parameters of the workpiece 12, after which the control unit generates control commands for the movement of the portal 2 along the Y axis, the movement of the carriage 5 along the X axis, the movement of the housing 8 with the working tool 9 along the Z axis, and also regulates the speed and pressure of the working tool 9 to the surface of the part 12.

The method is also implemented using the measuring module 15, which is fastened to the portal 14 (Fig. 4), which can move along the Y axis. The measuring module 15 is made, for example, in the form of a probe and is made to move along the X axis relative to the portal 14. First, the measuring module 15 scans the surface of the workpiece 12, with the subsequent development of control commands for the movement of the housing 8 with the working tool 9

The machine control unit controls the measurement process and the processing of the workpieces. Possible versions of the device are shown in table 1.

Claims (5)

1. A method for finishing a workpiece of a blade of a gas turbine engine, including measuring the geometric characteristics of the workpiece, comparing the measured shape of the workpiece with the theoretical shape of the finished part, determining the areas of the workpiece for finishing processing, forming the path of the working tool, setting cutting modes based on the measured data and performing finishing using a working tool in the form of a circle, characterized in that the workpiece is moved into the processing zone and produced by scanning geometrical parameters of the workpiece in orthogonal coordinates in the transverse, longitudinal and vertical directions along the Y, X, Z axes using the measuring module by uniformly moving it along the axis of the rotating workpiece, after which the data of the measured shape of the workpiece is transmitted to the control unit, in which mathematical processing is performed data, comparing the measured shape of the workpiece with the theoretical shape of the part and determining the set of areas for finishing the workpiece, on the basis of which the processing agotovki said working tool by means of its movement along three orthogonal coordinates Y, X, Z, wherein the removal is carried out the current parameters of the workpiece via force-torque sensor, which is transmitted to the control unit for generating control commands. 2. The method according to p. 1, characterized in that the working tool is rotated relative to the longitudinal axis of its body. 3. The method according to p. 1, characterized in that the workpiece during processing is rotated relative to its longitudinal axis with the possibility of fixing in a certain position. 4. A device for finishing processing of a workpiece of a blade of a gas turbine engine, comprising a base on which a portal is mounted with a workpiece, a working tool, a measuring unit and actuators for moving the tool and workpiece associated with the measuring unit and the control unit, characterized in that the portal is made movable relative to the base with the possibility of longitudinal movement along the Y axis, a workpiece feed manipulator, a measuring unit and a lateral movement carriage are mounted on it X X with a housing fixed on it for installing a replaceable working tool with the possibility of vertical movement of the tool relative to the Z axis, while the housing is additionally equipped with a torque sensor connected to the control unit, which has feedback from the movement drives of the portal, carriage, tool and manipulator with the workpiece, and the workpiece feed manipulator mounted on the base provides the possibility of a fixed position of the workpiece or its rotation around the Y axis during processing. 5. The device according to claim 4, characterized in that it is equipped with an additional movable portal mounted on the base, on which the measuring module is installed.

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