面向多主轴圆周阵列加工的整体叶盘磨抛机床设计与分析

Design and analysis of a grinding and polishing machine tool for blisks with multi-spindle circumferential array

  • 摘要: 针对航空发动机整体叶盘精加工效率低、加工一致性差和手工抛光的问题,根据叶盘结构和加工工艺特征设计了一种多主轴圆周阵列磨削抛光加工机床并研制了其原理样机,该机床包含多个主轴呈圆周阵列布置共同对一个叶盘的多个叶片进行加工。首先,基于分层设计方法优选出机床结构形式1Tw1Rw1Tt2Rt,包含3个旋转轴和2个直线轴实现5轴联动功能,机床结构方式更为紧凑且有利于实现多主轴同步加工。其次,基于多体系统动力学理论进行机构逆解分析,开展了机构运动学仿真验证和工作空间分析,运动学性能对比结果表明,与传统机床旋转轴相比,圆周阵列机床具有更好的运动性能。最后,搭建了机构原理样机并开展了叶盘叶片试件加工试验。结果表明,所加工试件误差范围−0.03~0.03 mm,满足叶片型面加工公差要求,验证了机床多主轴加工性能。

     

    Abstract: Addressing the issues of low efficiency, poor consistency, and manual polishing in the finishing of aeroengine integral blisks, a multi-spindle circumferential array grinding and polishing machine tool was designed based on the structure and processing characteristics of the blisks, and a prototype was developed. The machine tool consists of multiple spindles arranged in a circumferential array to process multiple blades of a single blisk. Firstly, based on the layered design method, the machine tool structure was optimized to be 1Tw1Rw1Tt2Rt, which includes three rotary axes and two linear axes to achieve five-axis linkage functionality. The machine tool structure is more compact and conducive to achieving multi-spindle synchronous machining. Secondly, inverse kinematics analysis was conducted based on multi-body system dynamics theory and graphical method of mechanism, followed by kinematic simulation verification and workspace analysis. The comparison results of kinematic performance show that compared with the traditional machine tool rotary axis, the circumferential array machine tool has better motion performance. Finally, a prototype of the mechanism was built and processing experiments on blisk blade specimens were carried out. The results showed that the error range of the processed specimens was −0.03 to 0.03 mm, meeting the processing tolerance requirements for the blade surface, verifying the multi-spindle processing performance of the machine tool.

     

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