基于虚拟驱动的整体叶盘电解加工在线测量系统开发

发布时间：2018-04-23 20:20

本文选题：电解加工 + 整体叶盘　；参考：《安徽理工大学》2015年硕士论文

【摘要】：整体叶盘是航空发动机等产品上的重要零件,其采用的加工方法主要有高速切削、电解加工、连接法、电火花加工,其中电解加工以其独特的优势将成为整体叶盘加工采用的主要方法之一。在整体叶盘加工试制过程中,通常需要对叶片进行多次测量并根据测量结果对试验方案进行调整。在过去采用离线测量方式,但每一次离线测量都需要把零件从机床上取下来,夹具调整与对刀比较麻烦,既耗时又费力,延长了零件的试制时间。为此开发一套用于整体叶盘电解加工的在线测量系统,研究该系统的构建方式、测量方法、数据处理与误差分析等,实现整体叶盘的在线测量、数据处理与结果输出,提高零件的测量效率。首先,研究了整体叶盘在线测量系统的结构与方法。构建的在线测量系统由控制器、测量驱动系统、数据处理与分析软件以及无线与有线通讯模块组成。该测量系统的驱动借助了电解加工机床原有的交流数字伺服驱动系统,在其硬件基础上利用运动控制器厂家提供的运动函数集开发相应的测量驱动软件,实现对机床各个运动轴的驱动,从而简化了测量系统的结构。测量头选用英国RENISHAW公司的RMP60机床测头,测量的数据通过无线网络发送到接受器,再通过有线网络传给计算机,进行数据处理与加工误差分析。其次,研究了整体叶盘测量系统的测量与数据处理方法。根据整体叶盘叶片的特点对测量路径进行了规划,在UG NX8.5软件平台上利用VisualC++开发了整体叶盘测量驱动软件,由软件生成测量运动路径并自动生成机床的运动程序并驱动机床运动,同时控制RMP60测头进行测量,对测量数据提取,在计算机中将提取的数据进行数据处理,在UG软件中利用NURBS样条等工具进行叶片的逆向建模,并利用软件提供的分析函数对叶片的误差进行分析,从而完成整体叶盘测量所需的驱动、测量与数据分析。最后,对开发的整体叶盘在线测量系统进行了应用。在某型号的整体叶盘电解加工试制过程中,对整体叶盘进行了在线测量与加工误差分析。测量结果表明：该在线测量系统可以实现模型数据匹配和运动轴的尺寸驱动以及驱动测头测量,并将数据导入软件中进行插值计算,生成叶片的测量模型,通过软件分析可知该整体叶盘的叶盆与叶背的距离公差在0.0254mm之间,角度公差为0.5。,而叶间的公差则略有不同,其距离公差为0.0255mm,角度公差为0.51。
[Abstract]:The integral vane is an important part of aero-engine and other products. The main machining methods are high speed cutting, electrolytic machining, connecting method, EDM, etc. Among them, electrolytic machining will become one of the main methods for the whole blade disk processing with its unique advantages. In the process of manufacturing and manufacturing the whole blade, it is usually necessary to measure the blade several times and adjust the test scheme according to the measurement results. In the past, off-line measurement was adopted, but each off-line measurement needs to remove the parts from the machine tool. The adjustment of the fixture is more difficult than the tool alignment, which is time-consuming and laborious, and prolongs the trial production time of the parts. In this paper, a set of on-line measuring system for integral blade plate electrolytic machining is developed. The construction mode, measuring method, data processing and error analysis of the system are studied. The on-line measurement, data processing and result output of the whole blade disk are realized. Improve the measuring efficiency of parts. Firstly, the structure and method of the system are studied. The on-line measurement system is composed of controller, measurement drive system, data processing and analysis software and wireless and wired communication module. The drive of the measuring system is based on the AC digital servo drive system of ECM machine tool. On the basis of its hardware, the corresponding measurement driving software is developed by using the motion function set provided by the motion controller manufacturer. The drive of each movement axis of the machine tool is realized, thus simplifying the structure of the measuring system. The head of the measurement adopts the head of RMP60 machine tool of RENISHAW Company of England. The measured data is transmitted to the receiver via wireless network and then transmitted to the computer through the wired network for data processing and processing error analysis. Secondly, the measurement and data processing methods of the whole blade disk measurement system are studied. According to the characteristics of the whole blade, the measuring path is planned, and the driving software of the whole blade is developed by using VisualC on UG NX8.5 software platform. The software generates the motion path of the machine tool and automatically generates the motion program of the machine tool and drives the movement of the machine tool. At the same time, the RMP60 probe is controlled to measure, the measurement data is extracted, and the extracted data is processed in the computer. In UG software, the NURBS spline and other tools are used to carry out the reverse modeling of the blade, and the error of the blade is analyzed by using the analysis function provided by the software, so that the driving, measuring and data analysis of the whole blade disk measurement are completed. Finally, the development of the whole blade disk online measurement system has been applied. The on-line measurement and machining error analysis were carried out in the trial production of a certain type of monolithic blade plate. The measurement results show that the on-line measurement system can realize the model data matching, the size drive of the moving axis and the measurement of driving probe, and the data are imported into the software to carry out interpolation calculation to generate the measuring model of the blade. Through the software analysis, the distance tolerance between the leaf basin and the back of the whole blade is between 0.0254mm and the angle tolerance is 0.5.The tolerance between the leaves is slightly different, the distance tolerance is 0.0255mm and the angle tolerance is 0.51m.
【学位授予单位】：安徽理工大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：V263.1

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