振动辅助电火花修整航空发动机叶片进排气边误差工艺参数优化及对比  

Optimization and Comparison of Trimming Parameters of Leading and Trailing Edges of Aero-Engine Blade by Vibration Aided EDM

作　　者：宋涛 龙金 闫步云 王笑影 马良奇 余祖元[1] SONG Tao;LONG Jin;YAN Buyun;WANG Xiaoying;MA Liangqi;YU Zuyuan(School of Mechanical Engineering,Dalian University of Technology,Dalian 116024,China)

机构地区：[1]大连理工大学机械工程学院

出　　处：《航空制造技术》2020年第4期48-53,共6页Aeronautical Manufacturing Technology

基　　金：国家科技重大专项(2017–VII–0004–0097);国家自然科学基金(91860134)

摘　　要：为解决航空发动机叶片经电解加工后进排气边缘存在的尺寸与形状误差,采用振动辅助电火花加工对其形状和尺寸误差进行粗加工修整。通过振动电极,造成狭小放电间隙的尺寸及放电绝缘液的压力变化,易于排屑,使得加工过程稳定,有利于提高加工效率。为了获得叶片边缘修整粗加工的最优加工工艺参数,以尺寸为(29×29×0.5)mm^3的GH4169镍基高温合金薄片为对象,进行了系列切断试验。由于影响电火花加工特性的因素很多,采用正交试验的方法探究了粗加工过程中脉冲放电电源的脉冲宽度、峰值电流、振动电极的幅值和频率对工件材料去除率的影响,确定最大加工效率的加工参数。试验结果表明,GH4169镍基高温合金的最优加工工艺参数为脉冲宽度4μs、峰值电流30A、振动幅值1.2μm、振动频率1200Hz,材料去除率达10.86mm^3/min。采用单因素试验法在同一加工参数下对比研究了不同工件材料对试验结果的影响。To correct the dimensional and shape errors of leading and trailing edges of aero-engine blade after electrochemical machining(ECM), experiments of rough machining in trimming process are carried out by electrical discharge machining(EDM). In vibration aided EDM, the discharge gap and pressure in the gap varies, resulting in debris escaping easily, leading to the stable process and improvement of machining efficiency. To obtain the optimal machining parameters in rough trimming of edges of aero-engine blade by EDM, extensive cutting experiments of GH4169 with dimensions of 29×29×0.5 mm^3 have been carried out. Based on primary experimental results, orthogonal experimental design is used to study the effects of peak current, pulse width, amplitude and frequency of vibration on material removal rate(MRR). The optimum processing parameters of GH4169 nickel base alloy are pulse on-time of 4μs, peak current of 30 A, vibration amplitude of 1.2μm, vibration frequency of 1200 Hz, and MRR is up to 10.86 mm^3/min. The influence of different workpiece materials on the experimental results is studied by single factor experimental method under the same processing parameters.

关 键 词：电火花加工(EDM) 镍基高温合金 正交试验设计 加工工艺参数 对比分析 

分 类 号：V263[航空宇航科学与技术—航空宇航制造工程] TG661[金属学及工艺—金属切削加工及机床]