Optimization For Blisk Compound And Efficient Powerful NC Milling Machine's Disk Milling Column

As a key component of new generation aero-engine which to achieve structural innovation and technological leapfrogging, blisk is widely used in advanced and high thrust-weight ratio aircraft engine for its outstanding merits. However, the materials of workblank are titanium alloy and high temperature alloy which are hard to manufacture, the structure of blisk is complex and the channel accessibility is difficult, the bending and torsion is large. All this made the blisk integrated manufacturing technology is extremely difficult, and foreign country's advanced manufacturing technology is strictly blocked to China. Therefore research on blisk slot rough milling methods and equipment has significant value in improving efficiency and reducing the cost.Currently, domestic blisk processing mainly relies on the imported five-axis machine tools, with the approach of layered cutting using plunge milling and side milling, the cost is high and the efficiency is low. To change this situation and localization blisk processing equipment, this paper studied on blisk compound and efficient powerful milling machine and its key processing technology, especially the key stress-carrying parts. Through the analysis of disk milling column's static and dynamic characteristics, the new machine will improve the machining efficiency, then to realize the high efficiency blisk slot rough milling, shorten the processing time, low the cost and improve the blisk manufacturing level of our country. The main contents are as follows:Firstly, based on the principle of three factors and three levels orthogonal experiment, the TC4 disc milling cutting experiments are tested. The disk milling's temperature, disk tool wear, metamorphic layers, milling forces of three direction and cutting vibration frequency are obtained. The three direction milling forces and cutting vibration frequency are used to analysis the disk milling column's static and dynamic characteristics. The analysis results are used to redesign the disk milling column to improve the static and dynamic characteristics.Secondly, based on the basic design principles of numerical control machine, integrated consideration of the functions of disk milling, plunge milling and side milling, the overall plan of blisk compound and powerful efficiency milling machine is proposed. The machine's 3-D model is established, main parameters are confirmed according to the processing requirements, and disk milling column is briefly introduced.Thirdly, based on the three direction disk milling force and cutting vibration frequency, which obtained by orthogonal experiments, combined with three kinds extremity milling situation, disk milling column's static and dynamic characteristics are analyzed. In the static analysis, disk milling column's three typical processing conditions' stiffness are analyzed according to actual cutting force by finite element analysis system ABAQUS. Then based on modal analysis method, disk milling column's first six orders of mode shapes and their frequencies are obtained. Meanwhile, use the method of harmonic response analysis, disk milling column's dynamic characteristic is studied.Finally, based on topology technology and cell structure technology, disk milling column's inner structure is optimized. Topological optimization determined disk milling column's inner materials removal steps, then the rib plate's arrangement are ensured. Cell structure method optimized the clearance hole's shape, size, number, rib plate's thickness etc. According to the optimized three kind cell structures, the new disk milling column's 3-D model is established. The finite element analysis indicates the new disk milling column's static and dynamic characteristics are improved, the disk milling column's mass also decreased.