整体叶盘磨抛检测一体化机床结构开发与装配工艺研究

发布时间：2018-05-27 21:32

本文选题：整体叶盘 + 叶片磨抛　；参考：《吉林大学》2015年硕士论文

【摘要】：整体叶盘是现代航空发动机的一种新型结构部件,目前已经在航空发动机风扇、压气机和涡轮上得到广泛应用,能有效地提高发动机的推重比。整体叶盘的结构同传统叶片和轮盘装配机构不同,它减少了榫头、榫槽及锁紧等装置,避免了榫根与榫槽间的气流损失。同时,整体叶盘的材料一般为钛合金和镍基合金等先进复合材料,其结构具有叶片薄、易变形、叶片间隙窄而深等特点。这样的材料和结构特点大大减轻了转子结构重量,提高了气动效率,改善工作时的气动效率和散热性能,从而使发动机的工作寿命和安全性更得到了很大提升。国外,数控铣削、电解加工、电火花加工、精密焊接、研磨抛光加工等方面有一定技术优势,使得整体叶盘制造技术已经趋于成熟。目前,国内叶片表面精加工主要还是依靠手动抛光工艺来实现,自动化程度很低,故整体叶盘的制造精度和质量难以保证,大大降低了整体叶盘的工作性能和使用寿命。此外,由于整体叶盘结构的特殊性,叶片型面的检测容易与其他叶片发生干涉,难以获得准确的叶片型面误差。本文针对上述问题,研发了一种集磨抛加工和在位测量于一体的整体叶盘磨抛机床。机床采用双立柱、XY,工作台的结构形式,七轴五联动,能够高效率、高精度地完成整体叶盘叶片的磨抛和测量工作。综合考虑整机的刚性、承载能力、加工范围等,确定了整体叶盘磨抛检测机床的技术指标和精度要求。对整机结构进行了详尽的结构设计,包括机床主体结构设计、各直线轴和旋转轴转动轴的驱动系统设计、砂带磨削工具系统和在线检测系统设计等；并针对设计的整机装配结构利用CATIA进行三维建模,导入至ANSYS Workbench14.5中进行受力分析、划分网格、结合面选取等前处理工作,通过有限元静力学分析获得整机装配体沿X、Y、Z轴三个方向的静刚度,通过模态分析和谐响应分析获得装配体的动态特性,找出更容易被动态激振力激发的模态阶数,避免整机运行时发生共振,以确保装配结构设计的合理性和安全性；制定合理的整机装配工艺,将整机装配工作分为：装配前期准备工作；床身-Y滑鞍-X轴工作台总成；Z轴立柱总成装配和布线以及油漆修补四个部分,从而完成整体叶盘磨抛检测机床的机械部分装配工作。
[Abstract]:Integral impeller is a new type of structural component of modern aero-engine, which has been widely used in aero-engine fans, compressors and turbines, which can effectively improve the thrust / weight ratio of the engine. The structure of the integral disk is different from that of the traditional blade and wheel assembly mechanism. It reduces the tenon, tenon and locking devices, and avoids the loss of air flow between the tenon root and the mortise groove. At the same time, the material of integral disk is titanium alloy and nickel base alloy, its structure is thin, easy to deform, the blade gap is narrow and deep. This material and structure features greatly reduce the weight of rotor structure, improve the aerodynamic efficiency, improve the aerodynamic efficiency and heat dissipation performance, thus greatly improve the working life and safety of the engine. Abroad, numerical control milling, electrolytic machining, EDM, precision welding, grinding and polishing have some technical advantages, which makes the manufacturing technology of the whole blade disk more mature. At present, the domestic blade surface finishing is mainly realized by manual polishing process, and the degree of automation is very low, so it is difficult to guarantee the manufacturing accuracy and quality of the whole blade disk, which greatly reduces the working performance and service life of the whole blade disk. In addition, because of the particularity of the whole leaf disk structure, the detection of blade shape surface is easy to interfere with other blades, and it is difficult to obtain the accurate blade shape surface error. In order to solve the above problems, a monolithic vane grinding and polishing machine which integrates grinding and in-situ measurement is developed in this paper. The machine adopts double column XY, the structure of worktable, seven axes and five linkage, which can finish the grinding and measuring work of integral blade with high efficiency and high precision. Considering the rigidity, bearing capacity and machining range of the whole machine, the technical index and precision requirement of the whole vane grinding and polishing testing machine are determined. The structure of the whole machine is designed in detail, including the design of the main structure of the machine tool, the drive system of each linear axis and the rotating axis, the belt grinding tool system and the on-line testing system, etc. In view of the whole machine assembly structure designed, 3D modeling is carried out by using CATIA, which is imported into ANSYS Workbench14.5 for force analysis, meshing, and combining with the pre-processing work such as surface selection, etc. Through finite element static analysis, the static stiffness of the assembly is obtained along the three directions of the XNY Z axis, and the dynamic characteristics of the assembly are obtained by modal analysis, and the modal order which is more easily excited by the dynamic excitation force is found out. Avoid the resonance when the whole machine is running to ensure the rationality and safety of the assembly structure design, formulate the reasonable assembly process, and divide the whole machine assembly work into: the preparatory work in the early stage of assembly; The assembly and wiring of Z-axis column assembly and paint repair are carried out in bed -Y sliding saddle -X axis worktable assembly, so as to complete the assembly of the mechanical part of the monolithic vane grinding and polishing testing machine.
【学位授予单位】：吉林大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：V263;V261

【参考文献】