群电极电火花高效加工镍基高温合金闭式整体叶轮

doi:10.3901/JME.2025.05.364

机械工程学报 ›› 2025, Vol. 61 ›› Issue (5): 364-374.doi: 10.3901/JME.2025.05.364

• 制造工艺与装备 • 上一篇

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群电极电火花高效加工镍基高温合金闭式整体叶轮

赵萌¹, 周明¹, 胡天赏¹, 杨建伟¹, 王衍学¹, 王亮², 徐佩³, 辛方晴³

1. 北京建筑大学机电与车辆工程学院北京 100044;
2. 北京华明亮科技有限公司北京 102308;
3. 中国航发动力股份有限公司西安 710016

收稿日期:2024-03-25 修回日期:2024-08-29 发布日期:2025-04-15
作者简介:赵萌，女，1999年出生。主要研究方向为电火花自适应加工，航空、航天发动机整体带冠叶轮制造。E-mail：zhaomeng0302@163.com;周明(通信作者)，男，1966年出生，博士，教授，硕士生导师。主要研究方向为电火花加工过程自适应控制；线切割加工过程自适应控制；线切割恒张力控制系统研究；航空、航天发动机整体带冠叶轮制造。E-mail：zhouming@bucea.edu.cn
基金资助:
慧眼行动快速应用资助项目(z22038)(HYXD-2021-01)。

High Efficient Electrical Discharge Machining Nickel-based Closed Integral Impeller with Gropes of Electrodes

ZHAO Meng¹, ZHOU Ming¹, HU Tianshang¹, YANG Jianwei¹, WANG Yianxue¹, WANG Liang², XU Pei³, XIN Fangqing³

1. School of Mechanical and Vehicle Engineering, Beijing University of Civil Engineering and Architecture, Beijing 100044;
2. Beijing Huamingliang Technology Co., Ltd., Beijing 102308;
3. AECC Aviation Power Co., Ltd., Xi'an 710016

Received:2024-03-25 Revised:2024-08-29 Published:2025-04-15

摘要/Abstract

摘要： 针对加工镍基高温合金闭式整体叶轮表面质量差和加工效率低这一问题，提出基于多变量自适应控制系统的群电极电火花加工工艺规划方法。该加工工艺分为粗、精加工两个阶段。粗加工中，搭建电火花多变量自适应控制系统，实时调整间隙电压、脉冲间隔和放电时间保证加工稳定性，同时分析脉冲宽度对加工镍基高温合金加工状态的影响，得到最优的粗加工工艺条件；精加工中，研究电极运动轨迹、极性效应、电流大小和加工余量对表面质量的影响，得到最优的精加工工艺条件。实验结果表明，所规划的工艺方法提高了加工效率且降低了叶轮表面粗糙度，最终加工叶片表面粗糙度为Ra1.2～1.5 µm，超过航空企业Ra3.2 µm的要求，同时加工效率成倍提高，本工艺方法在加工航空航天难加工、大扭曲复杂零件具有广阔的应用前景。

关键词: 群电极电火花加工, 闭式整体叶轮, 多变量自适应加工, 镍基高温合金, 工艺规划

Abstract: To address the challenges associated with poor surface quality and low efficiency in machining nickel-based superalloy closed integral impellers, a method of multi-electrode EDM process planning based on a multivariate adaptive control system is proposed. The machining process is categorized into rough and finish machining stages. During rough machining, a multivariate adaptive control system is established to dynamically adjust the gap voltage, pulse interval, and discharge time in real-time, ensuring machining stability. Concurrently，the influence of pulse width on the machining state is scrutinized to determine the optimal roughing process conditions. Furthermore，the effects of polarity effect, current size, and machining allowance on surface quality are examined to derive the optimal finishing conditions. Experimental findings demonstrate that the proposed process method enhances processing efficiency and diminishes impeller surface roughness. Ultimately, the machined blade's surface roughness measures Ra1.2-1.5 µm, surpassing the Ra3.2 µm requirements of aviation enterprises, with processing efficiency doubling. The process method exhibits promising application prospects in machining complex parts characterized by difficulty and significant distortion.

Key words: grouped electrode EDM, closed integral impeller, multi-electrode adaptive control, nickel-based superalloy, process planning

中图分类号:

TG661

赵萌, 周明, 胡天赏, 杨建伟, 王衍学, 王亮, 徐佩, 辛方晴. 群电极电火花高效加工镍基高温合金闭式整体叶轮[J]. 机械工程学报, 2025, 61(5): 364-374.

ZHAO Meng, ZHOU Ming, HU Tianshang, YANG Jianwei, WANG Yianxue, WANG Liang, XU Pei, XIN Fangqing. High Efficient Electrical Discharge Machining Nickel-based Closed Integral Impeller with Gropes of Electrodes[J]. Journal of Mechanical Engineering, 2025, 61(5): 364-374.

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群电极电火花高效加工镍基高温合金闭式整体叶轮

High Efficient Electrical Discharge Machining Nickel-based Closed Integral Impeller with Gropes of Electrodes

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