提高叶轮精度的非均匀余量工艺优化策略及试验研究

发布时间：2018-07-08 09:12

本文选题：整体叶轮 + 复杂曲面　；参考：《上海应用技术大学》2017年硕士论文

【摘要】：复杂曲面整体叶轮零件是高端工业装备中的核心零部件,具有结构复杂,曲面扭曲严重,去除材料率高,切削刚性差等特点,其曲面形状和制造精度直接影响装备的工作效率。但整体叶轮系零件制造过程中极易发生变形、振动、干涉等问题,制造难度极大,为当前计算机辅助制造的研究重点和难点之一。本文基于国内外研究现状,综述了整体叶轮零件的制造难点,介绍了叶轮制造技术的发展和未来的发展趋势,阐述了影响弱刚性零部件加工制造精度的主要因素,分析了整体叶轮零件超薄叶片产生加工变形的原因,提出了非均匀余量工艺优化策略。针对实际生产中的某型号环控系统内置轴流式叶轮叶片进行了非均匀余量工艺优化设计,使用NX高级仿真模块和ANSYS Workbench软件对其优化前后进行了变形分析、振动模态分析和谐响应分析,分析结果显示叶片刚度在三个方向优化率分别为58.82%,50%和37.5%,优化后的结构6阶模态有明显提升,证明该工艺优化策略对抑制切削颤振,减小加工时因切削振动导致的零件变型有效。论文在理论研究的基础之上,设计了案例叶轮从下料至零件产出的全流程工艺方案,NX CAM模块刀具轨迹规划、虚拟机床仿真加工并进行了非均匀余量工艺优化前后的切削对比试验。应用三维扫描曲面轮廓度检测方案对整体叶轮零件进行加工精度检测,检测结果显示,优化后的复杂曲面叶片吸力面的制造精度平均优化率为63.8%,压力面的制造精度平均优化率为48.84%,证明该工艺优化策略能有效提高整体叶轮超薄叶片的切削刚度,减小叶片在切削制造过程中产生的切削颤振,并且具有很强的实用性。对类似结构、类似尺寸整体叶轮零件的工艺性能提升能具有一定的指导意义。
[Abstract]:The integral impeller part with complex curved surface is the core part in high-end industrial equipment. It has the characteristics of complex structure, serious curved surface distortion, high material removal rate and poor cutting rigidity, etc. The shape and manufacturing accuracy of the surface directly affect the working efficiency of the equipment. However, the problems of deformation, vibration, interference and so on are easy to occur in the manufacturing process of integral impeller system parts, which is very difficult to manufacture, and is one of the most important and difficult problems in the research of computer-aided manufacturing. Based on the current research situation at home and abroad, this paper summarizes the manufacturing difficulties of integral impeller parts, introduces the development of impeller manufacturing technology and the development trend in the future, and expounds the main factors that affect the machining and manufacturing accuracy of weakly rigid parts. The causes of machining deformation of ultra-thin blades of integral impeller parts are analyzed, and the optimization strategy of non-uniform allowance technology is put forward. The non-uniform allowance process optimization design of an internal axial flow impeller blade is carried out for a certain type of environmental control system in practice. The deformation analysis before and after optimization is carried out by using NX advanced simulation module and ANSYS Workbench software. The results of vibration modal analysis show that the optimum rates of blade stiffness in three directions are 58.82% and 37.5%, respectively. The six order modes of the optimized structure are obviously improved. It is proved that the process optimization strategy can restrain the cutting chatter. It is effective to reduce the modification of parts caused by cutting vibration. On the basis of theoretical research, the paper designs the whole process plan of the case impeller from cutting material to parts output, and the tool path planning of NX CAM module is designed. Simulation machining of virtual machine tool and cutting contrast test before and after optimization of non-uniform margin technology are carried out. The machining accuracy of integral impeller parts is tested by 3D scanning curved surface contours detection scheme, and the results show that, The average optimization rate of manufacturing precision of suction surface of complex curved surface is 63.8%, and the average optimization rate of manufacturing precision of pressure surface is 48.84. It is proved that the process optimization strategy can effectively improve the cutting stiffness of the blade of integral impeller. The cutting chatter produced in cutting process is reduced, and it has strong practicability. It has certain guiding significance for the similar structure and the similar size integral impeller parts.
【学位授予单位】：上海应用技术大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TH161.1

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