三维电火花伺服扫描加工气膜孔轮廓模拟方法  

Contour Simulation Method for Servo Scanning Three-dimensional EDM of Diffusion Shaped Film Cooling Holes

作　　者：姚尧[1] 佟浩[1] 李勇[1] 崔英杰 YAO Yao;TONG Hao;LI Yong;CUI Yingjie(Department of Mechanical Engineering,Beijing Key Lab of Precision/Ultra-precision Manufacturing Equipments and Control,Tsinghua University,Beijing 100084)

机构地区：[1]清华大学机械工程系,精密超精密制造装备及控制北京市重点实验室,北京100084

出　　处：《电加工与模具》2025年第2期15-20,共6页Electromachining & Mould

基　　金：航空发动机及燃气轮机基础科学中心项目(P2022-A-IV-002-003);清华大学自主科研计划项目(20244186005)。

摘　　要：具有复合角出口的气膜冷却扩散孔具有很好的冷却性能,逐渐在先进航空发动机涡轮叶片上获得更多应用。三维电火花伺服扫描加工作为一种新的气膜冷却孔扩散结构加工方法,具有工具成本低、排屑效果好、可避免二次装夹误差且适用多种扩散结构等工艺优点。为实现模拟三维电火花伺服扫描加工气膜孔扩散结构轮廓,进而分析加工工艺中潜在的误差问题,提出了基于工具电极损耗长度计算的扫描轨迹重建及加工轮廓模拟方法。通过气膜冷却扩散孔的三维电火花伺服扫描加工实验,验证了该方法模拟实际加工轮廓的有效性和准确性,可用于分析加工过程中轮廓误差的来源。Diffusion shaped film cooling holes with compound-angle diffuser structures demonstrate superior cooling performance and have been applied in advanced aeroengine turbine blades gradually.Servo scanning three-dimensional electrical discharge machining(SS-3D EDM)is a novel method for processing diffusion structures of film cooling holes,offering advantages such as low tool costs,high debris removal efficiency,avoiding errors from secondary clamping and adaptability to various diffusion structures.To simulate the contour of diffusion structures processed by SS-3D EDM and to analyze potential errors in the machining process,a scanning path reconstruction and machining contour simulation method was proposed based on the calculation of tool electrode wear length.Through SS-3D EDM experiments on diffusion shaped film cooling holes,the validity and accuracy of this method in simulating actual machining contours are verified.It can be used to identify the sources of contour errors during the machining process.

关 键 词：电火花加工 三维伺服扫描 气膜冷却孔 扩散结构 加工轮廓模拟 

分 类 号：TG661[金属学及工艺—金属切削加工及机床]