Abstract
摘要

　 整體葉盤的出現(xiàn)是為了滿足市場的需求努示，與傳統(tǒng)轉(zhuǎn)子葉片和輪盤分離的裝配式葉盤相比虽捺，由于減少了傳統(tǒng)連接中的榫頭督阿，榫槽等裝配零件宣葡，葉輪邊緣負(fù)載降低，重量減輕高達(dá)30%畴制，同時(shí)由于避免了榫頭氣流損失也即減少動力消耗椰墩，從而也提高氣動效率并顯著提高功率，有助于減少燃油消耗和廢氣排放译快。追溯其發(fā)展歷史最初應(yīng)用到高壓壓氣機(jī)以及商用壓氣機(jī)末端上喊傻。是現(xiàn)代燃?xì)鉁u輪發(fā)動機(jī)中最具創(chuàng)新和挑戰(zhàn)的零部件。
　 The emergence of BLISK(Bladed integrated Disk) is in order to meet the market demand calls, comparing with conventional separable assembled rotor blades and disk counterparts, due to the reduction in the conventional connector assembly parts of the disk lugs, blade root groove, etc.; the rim load lower. The essential advantages are that they reduce weight up to 30% as well as reduce aerodynamic losses by avoiding disk lugs air leakage flows, thus improve aerodynamic efficiency and the power output, specially it enables reduce in fuel consumption and exhaust gas volume emissions. Retracing the history of Blisk development, it’s application initially used in high-pressure compressors and commercial compressors. It is the most innovative and challenging components of modern gas turbine engine.   

圖1: 整體葉盤模擬圖 Fig. 1: CAD Blisk

市場需求情況-應(yīng)對2020年需求的挑戰(zhàn)
Markt demond-Preparing for the Global Challenges of 2020
　 European aviation is experiencing a golden age which shows no sign of slowing. The continuous growth in world air transport - passengers and freight - experienced since the 1960s is set to continue at a rate of at least 5% a year over the next two decades. The latest Airbus forecasts indicate that this will mean a demand for 7600 new aircraft every decade - or a market estimated at 1300 billion Euros by 2019. As a vital sector in the European - and American - industrial dynamic, aircraft manufacture must therefore continue to innovate if it is to win these large markets. 
　 自從1960年以來航空業(yè)一直維持每年近5%的持續(xù)的年增長率攻内，歐洲航空空客業(yè)樂觀的預(yù)測下一個12年直到2019年的平均年增長率會保持不變褂磕，這也就意味著在2020年前將會有7200架新的飛機(jī)需求（客運(yùn)以及貨運(yùn)）/也即13000億歐元的市場份額。想要贏得這個巨大的市場份額匪傍，無論歐洲還是美國都必須全面投入新的技術(shù)革新來爭取您市。
　 The main objectives of the Aeronautics key action
? 35% reduction in production costs
? 20% reduction in development time
? 20% reduction in fuel consumption
? Increased reliability
? 10 dB reduction in sound level
? 20% reduction in CO2 emissions
? 80% reduction in NOx
? Optimization of airspace use
? 25% reduction in maintenance costs
? Reduced rate of accidents
數(shù)據(jù)來源Quelle:   http://ec.europa.eu/research/rtdinfo/en/28/aero1.html
航空業(yè)需要達(dá)到的重點(diǎn)行動目標(biāo)
? 生產(chǎn)成本降低35％
? 開發(fā)時(shí)間減少20％
? 燃料消耗減少20％
? 提高可靠性
? 噪音水平減少10分貝
? 減少20％的二氧化碳排放量
? 減少80％的氮氧化物
? 優(yōu)化空域使用
? 維護(hù)費(fèi)用降低25％
? 降低事故發(fā)生率

圖2:世界人口每人公里數(shù)飛行預(yù)測
Fig.: Flight amount in personal-kilometer worldwide

　 Growth in the production and use of blisks becomes clearly apparent. The trend is driven
also by increasing use in commercial engines. In the face of aggravating competition, individual AND cost saving manufacturing processes and moreover complete tailor made short foot prints- process chains need continuous optimization to satisfy market requirements.
　 整體葉盤的生產(chǎn)及應(yīng)用是顯而易見的。這種趨勢的主要緣由是來自民用需求役衡。
面對激烈的市場競爭茵休，獨(dú)立并且經(jīng)濟(jì)的工藝是首選，特別是量身訂制的縮短工藝路線路徑的全套方案更需要優(yōu)化以滿足市場的需求

　 整體葉盤主要制造技術(shù)
　 Main approaches for manufacturing blisk airfoils
　 整體葉盤目前主要加工工藝
　 The major alternative process for blisk machining:
? ?高效整體銑削
　 High Performance overall milling
? ?多軸聯(lián)動數(shù)控精密電解: 由于整體刀具成本的顯著降低手蝎，電解以及精密電解正在發(fā)展成為高溫合金材料整體葉盤最佳的加工工藝
　 Multi-axis linkage CNC PECM (precise electrochemical machining): Due to the significant tool cost saving, precise electro-chemical machining (PECM) is developing to become the most preferred manufacturing approach for blisk in nickel alloys.
　 埃馬克電化學(xué)有限公司最新開發(fā)的PO 900 BF精密多軸聯(lián)動高頻窄脈沖電解加工中心及全套交鑰匙工藝-從整體葉盤毛坯的初成行葉片套料加工(大量去除材料初步選擇性的實(shí)現(xiàn)葉片扭曲角度以及葉片輪廓)直到最終葉片型面成型完整的工藝鏈工件交鑰匙解決方案榕莺。
　 EMAG ECM GmbH developed its own new multi-axis PECM machining center and a whole tailor made process turnkey solution- from blisk rough majority material removing (masking roughing machining for majority material removing results in airfoil twisting pre-conture) till airfoil profile final conture.

　 1. 高效整體銑削
　 High Performance overall milling
　 This refers to cutting processes used to manufacture airfoils on 5- or 6-axis machine tools , with differentiation being made between rough and finish cutting. Typical processes of the kind are circular stagger milling in conjunction with high-performance tools and high-pressure internal cooling for the rough cut, The most common practice is point milling using a ball-end cutter and stripe or flank milling, etc., for the finish cut.
　 高效整體銑削技術(shù)是指在5或6軸加工中心加工上來進(jìn)行葉片的粗加工和精加工。典型工藝是循環(huán)交錯銑結(jié)合高效能的設(shè)備和高壓力內(nèi)部冷卻進(jìn)行粗切削棵介，葉盤精加工最常見的做法是用球面銑刀點(diǎn)球銑钉鸯，側(cè)銑與條紋銑等。
　 2. 多軸聯(lián)動數(shù)控精密電解: 由于整體刀具成本的顯著降低鞍时，電解以及精密電解正在發(fā)展成為高溫合金材料整體葉盤最佳的加工工藝
　 Multi-axis linkage CNC PECM (precise electrochemical machining): Due to the significant tool cost saving, precise electro-chemical machining (PECM) is developing to become the most preferred manufacturing approach for blisk in nickel alloys.
　 多軸聯(lián)動數(shù)控精密電解加工技術(shù)綜合了多軸聯(lián)動計(jì)算機(jī)數(shù)控和精密電解加工(基于電化學(xué)陽極溶解的原理來去除金屬材料)的加工兩者技術(shù)特點(diǎn)亏拉，工具陰極無損耗，無宏觀切削力逆巍，特別適宜加工壓氣機(jī)末端高溫區(qū)高溫合金或者鈦合金的變截面扭曲葉片的高難度整體葉盤整體葉盤及塘。
　 Multi-axis linkage CNC PECM (precise electrochemical machining) combined both advantages from CNC machining and PECM machining, there is not tool wear, no macro cutting force, especially suitable for high presuure compressor at end of the high-temperature zone with nikle alloy or titanium alloy of more twisted airfoil.
　 Precise electro-chemical machining (PECM) – an advanced technology for machining blisks
　 3.精密電解加工–先進(jìn)的整體葉盤加工工藝手段
　 Precise electro-chemical machining (PECM) derives from the widely used electro-chemical
　 machining (ECM) technique. It is characterized by very small working gap between the  electrode and the workpiece. This enables highly precise copy conformance of the workpiece shape to that of the cathode. Herewith, EMAG ECM GmbH develop its own cathode design software for airfoil radius or others profile zone compensation conformance during PECM Processes. Morevoer, this PECM process doesn’t generate any wear at the electrode, even when working on nickel alloys comparing with CNC milling process that are difficult to machine.
　 精密電解加工工藝(PECM)是源自于普通電解加工(ECM)，在加工陰極與工件之間的加工間隙較與后者的主要特點(diǎn)是加工間隙很小厚较。也因此可以達(dá)到良好的從陰極到工件復(fù)印效果坊蜂。在這里需要強(qiáng)調(diào)的是，埃馬克電化學(xué)公司開發(fā)了自己獨(dú)立的陰極設(shè)計(jì)軟件蚤岗，此軟件可以在精密電解工藝過程中對葉片的進(jìn)排氣R角以及相對型面區(qū)域進(jìn)行自動補(bǔ)償卢俯。另外，此工藝與傳統(tǒng)的數(shù)控銑削工藝相比变硬，乃至加工鎳基合金材料的整體葉盤也不會產(chǎn)生任何陰極消耗氢熏。
　 Because of the narrow working gap between electrode and workpiece, good exchange of the electrolyte is ensured only provided the electrode is set in an osccillating motion. In synchronism with the oscillating motion, a direct current pulse (material removal pulse) is superimposed and material is removed only when the gap is at its narrowest. This appreciably reduces the effective feed rate. EMAG ECM GmbH develp this technique with it new machine PO 900 BF with it the machining tolerances of airfoil ≤0,06mm (shape) and Surface quality of suitable materials of Ra ≤0,2 μｍcan be reachable.
　 由于工件與電極之間較窄的加工間隙想触，電解液的充分交換需要通過電極的振動才能完成，在振動過程中仲蔼，在電極與工件接觸最近的時(shí)候或者說振動幅最大時(shí)配給電流晾充，此電流進(jìn)行材料去除加工， 顯然整體的加工進(jìn)給速度會降低些搅，埃馬克電化學(xué)有限公司最新開發(fā)的PO 900 BF精密多軸聯(lián)動高頻窄脈沖電解加工中心可以最終達(dá)到葉片型面輪廓精度≤0,06mm一般高溫合金材料表面光潔度Ra ≤0,2 μｍ崭湾。

圖3:精密振動電解加工原理  Fig. 3: PECM Eccentric vibration theory

圖4: 機(jī)械振動與電脈沖配合的復(fù)合機(jī)械電加工
Fig. 4: Puls-ECM current combined with Oszillation (Puls-Packet)

　 4．工藝對比舉例
      Examples of Process Comparison
　 相比較高效整體銑削計(jì)算復(fù)雜，另外整體刀具加工成本也很高乏呐。
　 舉例在加工整體葉盤直徑約600mm猛蔽，材料為高溫合金，葉片數(shù)量70片以上灵寺，葉片單邊尺寸面積在12cm2多軸聯(lián)動數(shù)控精密電解與銑削的工藝路線以及成本對比見如下表格:
　 Comparing with the   High Performance overall milling as well as its tooling cost is also very expensive.  The following comparing sheet shows some simple process foot print and cost comparison between High Performance overall milling and Multi-axis linkage CNC PECM for blisk machining of a blisk with diameter around 600mm, material is nickel base alloy, the number of airfoils is more than 70, the machining area of each foil single side is around 12cm2 :

　 5. 埃馬克多軸聯(lián)動數(shù)控精密電解整體葉盤加工可達(dá)到的工藝指標(biāo)
　 埃馬克電化學(xué)有限公司最新開發(fā)的PO 900 BF精密多軸聯(lián)動高頻窄脈沖電解加工中心及全套交鑰匙工藝-從整體葉盤毛坯的初成行葉片套料加工(大量去除材料初步選擇性的實(shí)現(xiàn)葉片扭曲角度以及葉片輪廓)直到最終葉片型面成型完整的工藝鏈工件交鑰匙解決方案曼库。
EMAG ECM GmbH developed its own new multi-axis PECM machining center and a whole tailor made process turnkey solution- from blisk rough majority material removing (masking roughing machining for majority material removing results in airfoil twisting pre-conture) till airfoil profile final conture.
●  葉片型面輪廓精度≤0,06mm
     Achievable tolerances of airfoil ≤0,06mm (shape)
●  一般高溫合金材料表面光潔度Ra ≤0,2 μｍ
    Surface quality of suitable materials of Ra ≤0,2 μｍ
●  采用數(shù)控多軸聯(lián)動電解工藝進(jìn)行葉片套料加工,其進(jìn)刀速度≤ 2mm/min
     EMAG Multi-axis linkage CNC machining with infeed rate for airfoil ECM rough machining step is ≤ 2mm/min.
●  采用數(shù)控多軸聯(lián)動精密電解加工工藝，其進(jìn)刀速度約為0,1-0,2mm/min(葉片套料加工余量1mm )略板，并不會因?yàn)槿~片面積以及材料以及幾何尺寸都會對進(jìn)刀速度的提高產(chǎn)生顯著影響凉泄。
      EMAG Multi-axis linkage CNC machining with infeed rate for finish machining is 0,1-0,2mm/min. (around 1mm stock). In a wide range of geometries infeed is independent of foil area or size, this means cycle time is constant without increase.
●  埃馬克多軸聯(lián)動數(shù)控精密電解工藝是完整工藝，不需要之后拋光以及對于葉片進(jìn)排氣邊緣進(jìn)行再次加工
     EMAG Multi-axis linkage PECM blisk machining process, there is no subsequent machining required like polishing or airfoil edge machining.
●  埃馬克多軸聯(lián)動數(shù)控精密電解工藝是完整工藝是刀具無損耗工藝蚯根，在同一型號葉盤下的所有葉片可以使用同一套陰極制具完成加工，并多次使用胀糜。
     EMAG Multi-axis linkage PECM blisk machining process in principle is free of wear. This means hundreds of foils can be machined with the same tooling.
●  埃馬克多軸聯(lián)動數(shù)控精密電解機(jī)床的投資可以視客戶具體加工整體葉盤的尺寸以及電流配備颅拦，電解液系統(tǒng)配備進(jìn)行特制化量身訂制的投資。
     EMAG Multi-axis linkage PECM blisk machine investment costs depend on the size of the workpieces. Equipment is completely adjustable to customer requests regarding electrical power supply and filtration system.

圖5: EMAG PECM PO 900 BF 精密五軸電解加工中心
Fig. 5: EMAG PECM PO 900 BF Machine Center
 

（埃馬克公司供稿）

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