CN101062526A - Milling method for turbocharger air compressor blade wheel - Google Patents
Milling method for turbocharger air compressor blade wheel Download PDFInfo
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- 238000003801 milling Methods 0.000 title claims abstract description 19
- 238000003754 machining Methods 0.000 claims abstract description 14
- 238000005259 measurement Methods 0.000 claims abstract description 10
- 238000012545 processing Methods 0.000 claims description 29
- 238000000034 method Methods 0.000 claims description 25
- 230000008676 import Effects 0.000 claims description 24
- 230000008569 process Effects 0.000 claims description 20
- 238000005520 cutting process Methods 0.000 claims description 14
- 238000005516 engineering process Methods 0.000 claims description 14
- 238000004088 simulation Methods 0.000 claims description 12
- 238000013461 design Methods 0.000 claims description 7
- 238000009434 installation Methods 0.000 claims description 4
- 238000013178 mathematical model Methods 0.000 claims description 3
- 238000003672 processing method Methods 0.000 claims description 3
- 239000012467 final product Substances 0.000 abstract 1
- 101100203174 Zea mays SGS3 gene Proteins 0.000 description 8
- 238000010586 diagram Methods 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 239000004411 aluminium Substances 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 238000005495 investment casting Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 238000012795 verification Methods 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
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- 238000012360 testing method Methods 0.000 description 1
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Abstract
The invention relates to the milling method of turbine supercharging impeller. It inputs data of the impeller, clipping the blank, programming for five shaft digital control, analog after treatment G code of the digital program, digital controlled machining of the five shaft, coordinate measurement, and machining of the final product. It shortened machining cycle from forty eight hours to sixteen hours, with impeller profile error no big than 0. 1mm, low in cost, high in efficiency.
Description
Technical field: the invention belongs to the Machining Technology field, be specifically related to a kind of engine supercharger compressor impeller processing method, particularly a kind of small sized turbine booster centrifugal-flow compressor impeller milling method.
Background technology: the effect of supercharging is to be pressed into air in advance, increases the atmospheric density in the cylinder, and fuel is fully burned.Compressor impeller is the turbocharger vital part, by rotation at a high speed, utilizes the centrifugal action Compressed Gas, realizes the purpose of supercharging, and its aerodynamic characteristic and structural strength directly influence the properties of product of whole booster.
Compressor impeller is made of complex-curved blade, and profile error complicate fabrication process generally adopts casting aluminium material, by mould, hot investment casting moulding.Along with the development of CAD/CAM technology, the appearance of the perfect day by day and High Speed Milling Operation numerical control device of five-shaft numerical control process technology directly causes the impeller manufacturing that basic variation has taken place.
One, along with the raising of engine power and the restriction of piggyback pod installing space, the power per liter that increases unit volume has become the target of new type power development.This is to the demands for higher performance of booster, have only the rotating speed of raising could satisfy the demand that reaches high pressure ratio, impeller takes turns that all linear velocity 500m/s are above, when compressor delivery temperature surpasses 200 ℃, casting aluminium material can not satisfy long-time maintainability requirement.
Two, usually under the low-pressure ratio situation, the compressor impeller of small-sized booster all adopts hot investment casting, but its blade profile is complicated, must carry out the mould design, and the construction cycle is longer.Particularly at the alternatives formulation initial stage, utilize verification experimental verification to carry out multi-scheme when preferred, if adopt traditional mold production process, can consume a large amount of lead time and cost.
Summary of the invention: purpose of the present invention is just in order to solve the deficiencies in the prior art, and proposes a kind of milling method of turbo-charger blower impeller.
Technical scheme of the present invention: a kind of milling method of turbo-charger blower impeller the steps include:
1. import compressor impeller blade profile data: the blade profile data of form input blade according to the rules define the features such as import, outlet fillet, meridional channel shape, blade root portion fillet of blade simultaneously;
2. the clamping of blank: impeller blank installation way is that centre bore clamps, and three pin holes location of workpiece bottom reduce the distance of impeller programming center to the lathe A axle centre of gyration as far as possible;
3. five-shaft numerical control programming: according to the planform of impeller, be divided into operations such as fluting, wheel hub processing, blade processing, import and export cavetto, select different strategies to carry out numerical control programming at different operations;
4. the analogue simulation of numerical control program postposition is handled G code; Carry out machining simulation on the lathe mathematical model, simulation cutter, workpiece relative motion and machine tool motion situation check to be interfered, and avoid the generation of colliding, and determine the cutter compensation value simultaneously;
5. five-shaft numerical control processing: numerical control program is passed in the digital control system of five machining centers, establishment operation main program, recursive call is program separately, finishes the processing of impeller;
6. three-dimensional coordinates measurement detects: the point along on the curved surface direction vector measurement blade surface, point coordinates and spoon of blade cad model are compared, and analytical error is revised programming technology;
7. processed finished products.
Purpose of the present invention also can be further perfect by following steps: according to the design feature of impeller, it is long to calculate passage minimum widith and maximum cutting edge, selects big tapering minor diameter structure cutter for use, and numerical control programming, processing are carried out in the subregion; The blank fluting adopts multilayer, little cutting output, fast feeding Cutting Process; In the roughing operation, adopt the symmetrical grooving mode;
Beneficial effect of the present invention: adopt this technology, shortened to 16 hour by 48 hours process time, blade profile profile tolerance error≤0.1mm, and cost is low, the efficient height.
Description of drawings: the present invention has 7 width of cloth accompanying drawings, and wherein Fig. 1 is a most preferred embodiment of the present invention, also can make the accompanying drawing of specification digest.
Fig. 1: process chart of the present invention;
Fig. 2: blade wheel structure schematic diagram of the present invention;
Fig. 3: vane type line schematic diagram of the present invention;
Fig. 4: blade import fillet schematic diagram of the present invention;
Fig. 5: anchor clamps of the present invention are revised design diagram;
Fig. 6: impeller subregion processing schematic diagram of the present invention;
Fig. 7: blade fine finishining track schematic diagram of the present invention.
The specific embodiment: most preferred embodiment of the present invention is further described below in conjunction with accompanying drawing.
As shown in Figure 1, a kind of milling method of turbo-charger blower impeller, 1. import compressor impeller blade profile data: the blade profile data of form input blade according to the rules define the features such as import, outlet fillet, meridional channel shape, blade root portion fillet of blade simultaneously;
2. the clamping of blank: impeller blank installation way is that centre bore clamps, and three pin holes location of workpiece bottom reduce the distance of impeller programming center to the lathe A axle centre of gyration as far as possible;
3. five-shaft numerical control programming: according to the planform of impeller, be divided into operations such as fluting, wheel hub processing, blade processing, import and export cavetto, select different strategies to carry out numerical control programming at different operations;
4. the analogue simulation of numerical control program postposition is handled G code; Carry out machining simulation on the lathe mathematical model, simulation cutter, workpiece relative motion and machine tool motion situation check to be interfered, and avoid the generation of colliding, and determine the cutter compensation value simultaneously;
5. five-shaft numerical control processing: numerical control program is passed in the digital control system of five machining centers, establishment operation main program, recursive call is program separately, finishes the processing of impeller;
6. three-dimensional coordinates measurement detects: the point along on the curved surface direction vector measurement blade surface, point coordinates and spoon of blade cad model are compared, and analytical error is revised programming technology;
7. processed finished products.
Concrete steps: (1) input blade profile data file
As shown in Figure 2, the centrifugal-flow compressor impeller is a rotary structure, mainly contains several sections and constitutes, and around the tapered revolving body that axle 1 rotation forms, is called wheel hub 2 by the camber curve; Inlaying the blade of one or two type on wheel hub 2, be called linear leaf 3 and short blade 4, every group of blade evenly distributes around axle 1; There is knuckle the junction of blade 3,4 and wheel hub 2, is called long and short root of blade fillet 5,6; Each long and short blade 3,4 all is made of suction surface 9,7 and pressure face 8,10, import fillet 15,13 and outlet fillet 11,12.The molded lines of blade outermost is called wheel rim 14, according to the feature at each position, adopts the data description of different types, forms the file of following several patterns.
A. linear leaf document format data
This document form is to describe the suction surface of linear leaf and the shape of pressure face, as shown in Figure 3, is made of the straight line group of wheel rim 14 to wheel hub 2 on suction surface 9, and the straight line end points is respectively wheel rim coordinate points 3a and wheel hub coordinate points 3b; The shape description of pressure face 8 is with top identical.
8--the number of blade
75--counting of each face
The data of 1 Suction suction surface
0 Shroud wheel rim coordinate points Hub wheel hub coordinate points
Period X value Y value Z value X value Y value Z value
1 49.562 -0.155 -48.143 17.114 -0.768 -46.846
2 ……
……
The data of pressure face similarly
B. short blade document format data
This document form is to describe the suction surface of short blade and the shape of pressure face, and is identical with the linear leaf document format data.
C. blade meridian molded lines file format
This document form is a shape of describing wheel rim 14 and wheel hub 2 molded lines.
77 count
Shroud wheel rim molded lines
Z coordinate figure R coordinate figure
-55 50.067
……
The wheel hub molded lines similarly
D. linear leaf import and export fillet file format
This document form is to describe the shape that linear leaf is imported and exported fillet, as shown in Figure 4, in the import 15 of blade, from wheel rim 14 to wheel hub 2, several cross section 15a, 15b, 15c, 15d radially distribute, on each cross section, intersect by blade suction surface 8, pressure face 9 and cross section, form vane type line 15g, with elliptic arc 15e and the tangent formation fillet of vane type line 15g molded lines 15f, by control long axis of ellipse and minor axis ratio, obtain different rounded shapes.
Blade exit is described identical therewith.
4 describe the quantity in inlet side fillet cross section
2 describe the quantity in outlet fillet cross section, limit
The import rounded shapes is described
The ellipse ratio of wheel rim, wheel hub
2; The ellipse long and short shaft ratio of wheel rim cross section fillet
2; The ellipse long and short shaft ratio of 33% cross section fillet
2; The ellipse long and short shaft ratio of 66% cross section fillet
2; The ellipse long and short shaft ratio of wheel hub cross section fillet
The outlet rounded shapes
The ellipse ratio of wheel rim, wheel hub
2.5; The ellipse ratio of wheel rim cross section fillet
2.5; The ellipse ratio of wheel hub cross section fillet
E. short blade import and export fillet file format
This document form is to describe the shape that short blade is imported and exported fillet, and is identical with the linear leaf document format data.
F. root of blade fillet file format
This document form is a shape of describing the root of blade fillet, and as length value, import is 0.0 according to the percentage of blade arc length, and outlet is 1.0.
2; The quantity of root of blade fillet is described
The root fillet of linear leaf suction surface
Percentage length radius value
0.0 1.5
1.0 1.5
The form of the root fillet of the root fillet of the root fillet of linear leaf pressure face, short blade suction surface, short blade suction surface similarly.
(2) clamping of design of Clamping Apparatus and blank
Shown in Fig. 5 a, if milling impeller blank 19 adopts conventional scroll chuck 18 mode clampings, workpiece programming initial point 16 and the lathe A axle centre of gyration 17 distances are bigger, cause five-axle linkage processing stroke lengthening.
Change installation way thus, shown in Fig. 5 b, clamp structure is changed into centre bore 21 and is clamped, three pin holes, 22 location on the workpiece, reduce workpiece programming initial point 16 to the lathe A axle centre of gyration 17 distances, shortened the radius of gyration of impeller blank 19 relative lathe A axles 17, made cutter in working angles, the workpiece stroke shortens relatively, has improved the relative cutting speed of cutter and workpiece.Simultaneously, increase the steadiness of blank.
(3) five-shaft numerical control programming
Numerical control programming technology can be divided into: fluting, wheel hub processing, three parts of blade fine finishining, and take different Processing Strategies to programme at different operations, to obtain the fastest stock-removing efficiency and best cutting quality.
According to the design of part feature, optimize and select milling cutter, as shown in Figure 6, at the flow passage structure of impeller, wheel hub 2 place's runners are narrow, and wheel rim 14 place's runners are wide, and cutter should be selected big tapering, minor diameter structure for use as far as possible.In this example, relatively find: in the R01 operation of fluting processing and milling upper slot A1, on processing characteristics and intensity, use φ 8mm * 5 ° tapering cutter obviously to be better than the cutter of φ 10mm * 4 ° by engineer testing.
First: fluting, as shown in Figure 6, the width distribution situation of radial-flow type centrifugal compressor runner is to be narrowed down gradually to wheel hub 2 by wheel rim 14, is narrowed down gradually to outlet 11 by import 15.Thus blade surface is divided into 23,24,25,26,27,28,31,32,33,34 totally 10 zones, passage is divided into 31,32,33,34,35 totally 5 zones.
In the programming process,, form 10 cutting zones: be respectively import upper slot A1, i.e. the zone of 24 and 35 combinations according to the combination of above-mentioned zoning; Import lower channel A2, i.e. zone of 23 and 35 combinations or the like.We select for use different cutters to carry out multilayer (every layer thickness 1.0mm), little cutting output, fast feeding milling to each zone, adopt triangle tool path pattern 36.Present embodiment technology sees the working process parameter table for details.
Fluting (roughing) process parameter table unit: mm
| Title | Cutting zone | Cutter parameters | Cut wide | Cutting-in | Feeding | Rotating speed | Surplus | ||
| Blade | Import and export | Wheel hub | |||||||
| R01 | Upper slot A1 | Φ8×5° | 8 | 1.0 | 1000 | 5000 | S0.5 H0.2 | 0.25 | 0 |
| R02 | Outlet upper slot right district CR1 | Φ8×5° | 8 | 1.0 | 1000 | 5000 | 0.2 | 0.6 | 0.1 |
| Other regional manufacturing procedure is similarly ... | |||||||||
Second portion: wheel hub processing and blade semifinishing.In blade half finish-milling operation, divide the step of removing in the roughing process for 2～3 times, for the blade finishing step provides uniform chipping allowance.
In finish-milling wheel hub 2 surperficial operations, as shown in Figure 6, adopt the processing of some position, by import 15 to exporting 11, repeatedly reciprocating type fast feed, hub surface should leave the tool marks consistent with airflow direction.This case process sees the working process parameter table for details.
Semifinishing process parameter table unit: mm
| Title | Cutting zone | Cutter parameters | Cut wide | Number of times | Feeding | Rotating speed | Surplus | ||
| Blade | Import and export | Wheel hub | |||||||
| F01 | Half finish-milling linear leaf | R1.5×4° | 2pass | 140 | 3000 | 0.1 | 0.1 | 0.5 | |
| F51 | Half finish-milling short blade | R1.5×4° | 2pass | 140 | 3000 | 0.1 | 0.1 | 0.5 | |
| H01 | Mill hub surface | R1.5×4° | 1.2 | 1500 | 8000 | 0.3 | 0.25 | 0 | |
Third part: blade fine finishining and outlet fillet cavetto, as shown in Figure 7, cutter side edge 37 processing of adopting, the blade root fillet is a definite value in this example, selects the bulb tapering milling cutter of identical R value according to fillet R value, suction surface 9, pressure face 8 and blade root fillet 5 are in the blade profile finishing step, the time processing moulding enters from the impeller outlet 11 of impeller outlet pressure face 8, walks around impeller inlet 15, form blade import fillet, mill out from the impeller outlet 11 of impeller suction surface 9.In this operation, suitably reduce feed speed, improve rotating speed.
In outlet fillet 11 cavetto operations, adopt slotting miller skill to finish.This case process sees the working process parameter table for details.
Fine-processing technique parameter list unit: mm
| Title | Cutting zone | Cutter parameters | Cut wide | Number of times | Feeding | Rotating speed | Surplus | ||
| Blade | Import and export | Wheel hub | |||||||
| T01 | Insert and mill the linear leaf outlet | R1.5×4° | 25pass | 600 | 6500 | 0 | 0 | 0 | |
| F02 | The finish-milling linear leaf | R1.57×1° | 1pass | 60 | 3500 | 0 | 0 | 0 | |
| The short blade operation is similarly ... | |||||||||
(4) machining simulation
In VERICUT software, set up blank model, fixture model, lathe model, use cutter model and corresponding handle of a knife model.
Top numerical control program is converted to the G code program, be input in the VERICUT software, carry out machining simulation according to process sequence, simulate actual process, further determine cutter parameters and cutter clamping length,, reduce the length that cutter stretches out as far as possible according to the situation of machining simulation, to improve the intensity of cutter, determine every simultaneously the cutter benefit value of cutter.
(5) five-shaft numerical control processing
G code is input in the digital control system of five machining centers.On the digital control system of the work in-process heart, work out roughing, semifinishing and fine finishining main program respectively according to technology, each main program calls corresponding G code program respectively.
The roughing main program, when carrying out impeller roughing, divide 360 degree, fluting G code subprogram above carrying out according to the linear leaf number average, stressed evenly for guaranteeing the workpiece cutting, should adopt symmetrical grooving, in this example, impeller is made of 8 long 8 short blades as far as possible, behind 0 degree direction fluting, should open second groove in 180 degree directions, afterwards 45 degree, 225 degree, fluting successively.The detailed procedure inventory of this example is seen the roughing main program in the appendix inventory.
The semifinishing main program comprises wheel hub processing and blade semifinishing, is processed successively according to above-mentioned technology table by 0 degree beginning.The detailed procedure inventory of this example is seen the semifinishing main program in the appendix inventory.
The fine finishining main program comprises blade fine finishining and outlet fillet cavetto, is processed successively according to above-mentioned technology table by 0 degree beginning.The detailed procedure inventory of this example is seen the fine finishining main program in the appendix inventory.
(6) compressor impeller three-dimensional coordinates measurement
Utilize three-coordinates measuring machine and curved surface analysis software, the spoon of blade of processing impeller is measured and error analysis.Point along on the curved surface direction vector measurement blade surface compares point coordinates and spoon of blade cad model, and analytical error is revised programming technology; If measurement data satisfies the design error requirement, formal converted products then.
Annex: program listing
Roughing main program inventory
0 BEGIN PGM ROUGH MM; The roughing program begins
1 CYCL DEF 7.0DATUM SHIFT; Rotating the C axle is 0 degree position
2 CYCL DEF 7.1C+0
3 CALL LBL1; Call LBL1 subprogram (roughing subprogram)
4 CYCL DEF 7.0DATUM SHIFT; Rotating the C axle is 180 degree positions
5 CYCLDEF 7.1C+180
6 CALL LBL 1 call LBL1 subprogram (roughing subprogram)
Process in 45 degree positions
Process in 225 degree positions
Or the like;
100 END PGM ROUGH MM; EP (end of program)
101 LBL1; LBL 1 subprogram begins
102 ；R01 G CODE
Call cutter
108 CALL PGM R01.I; Call the G code program of R01.I
109 ；R02G CODE
Call cutter
117 CALL PGM R02.I; Call the G code program of R02.I
Or the like
300 LBL0; End of subroutine
Semifinishing main program inventory
0 BEGIN PGM SEMI MM; The semifinishing program begins
1 CYCL DEF 7.0DATUM SHIFT; Rotating the C axle is 0 degree position
2 CYCL DEF 7.1C+0
3 CALL LBL 1; Call LBL1 subprogram (semifinishing subprogram)
Process in 45 degree positions
Or the like;
100 END PGM SEMI MM; EP (end of program)
101 LBL1; LBL 1 subprogram begins
102 ；F01 G CODE
Call cutter
108 CALL PGM F01.1; Call the G code program of linear leaf semifinishing F01.I
In like manner, carry out the G code of short blade semifinishing F51.I
115 ；H01 G CODE
Call cutter
119 CALL PGM H01.I; Call the G code program of wheel hub processing H01.I
130 LBL0; End of subroutine
Fine finishining main program inventory
0 BEGIN PGM FINISH MM; The fine finishining program begins
1 CYCL DEF, 7.0 DATUM SHIFT; Rotating the C axle is 0 degree position
2 CYCLDEF 7.1 C+0
3 CALLLBL 1 call LBL1 subprogram (semifinishing subprogram)
Process in 45 degree positions
Or the like;
100 END PGM FINISH MM; EP (end of program)
101 LBL1 LBL, 1 subprogram begins
102 ；T01 G CODE
Call cutter
108 CALL PGM T01.I; Call the G code program of milling linear leaf outlet fillet T01.I of inserting
In like manner, carry out the G code of short blade outlet fillet T51.I
Call cutter
119 CALL PGM F02.I; Call the G code program of linear leaf fine finishining F02.I
In like manner, carry out the G code of short blade fine finishining F52.I
130 LBL0; End of subroutine
Claims (3)
1, a kind of milling method of turbo-charger blower impeller is characterized in that: its step is
1. import compressor impeller blade profile data: the blade profile data of form input blade according to the rules define the features such as import, outlet fillet, meridional channel shape, blade root portion fillet of blade simultaneously;
2. the clamping of blank: impeller blank installation way is that centre bore clamps, and three pin holes location of workpiece bottom reduce the distance of impeller programming center to the lathe A axle centre of gyration as far as possible;
3. five-shaft numerical control programming: according to the planform of impeller, be divided into operations such as fluting, wheel hub processing, blade processing, import and export cavetto, select different strategies to carry out numerical control programming at different operations;
4. the analogue simulation of numerical control program postposition is handled G code; Carry out machining simulation on the lathe mathematical model, simulation cutter, workpiece relative motion and machine tool motion situation check to be interfered, and avoid the generation of colliding, and determine the cutter compensation value simultaneously;
5. five-shaft numerical control processing: numerical control program is passed in the digital control system of five machining centers, establishment operation main program, recursive call is program separately, finishes the processing of impeller;
6. three-dimensional coordinates measurement detects: the point along on the curved surface direction vector measurement blade surface, point coordinates and spoon of blade cad model are compared, and analytical error is revised programming technology;
7. processed finished products.
2, the processing method of a kind of turbo-charger blower impeller according to claim 1, it is characterized in that: according to the design feature of impeller, it is long to calculate passage minimum widith and maximum cutting edge, selects big tapering minor diameter structure cutter for use, and numerical control programming, processing are carried out in the subregion.
3, the processing method of a kind of turbo-charger blower impeller according to claim 1 is characterized in that: adopt multilayer, little cutting output, fast feeding cutting Programming Strategy in the fluting operation, adopt the symmetrical grooving mode in the process.
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2006
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