Electrode Motion Path Search and Optimization Method for EDM with Closed Blisk
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摘要: 针对闭式整体叶盘电火花成形加工时电极造型复杂、无干涉运动轨迹难以搜索等问题，研究了闭式整体叶盘的电火花加工电极设计方案，提出了一种电极结构及其运动轨迹设计方法。建立了成形电极减厚拆分原则，构造了直纹曲面的成形电极分型面；基于随机方向法进行了电极运动轨迹的搜索求解，得到了每个节点处电极上端面中心点的无干涉运动轨迹坐标；基于NURBS曲线对电极运动轨迹坐标点做出了拟合优化；进行了电极运动轨迹验证实验研究，实验结果表明叶片型面误差为±0.08 mm，满足了闭式整体叶盘的技术指标要求。研究表明，提出的电极结构及运动轨迹搜索优化方法适用于闭式整体叶盘的电火花加工，可作为此类问题的一种有效解决方案。Abstract: In order to solve the problem of complex electrode modeling and non-interference motion path searching for electric discharge machining (EDM) with closed blisk, the processing scheme of EDM for closed blisk is studied, an electrode structure and its motion path design method is proposed. The principle of electrode separation is established, the ruled surface is constructed as the electrode parting surface. The search process of the electrode motion path is completed based on the stochastic direction method, and the optimal coordinates of the electrode upper surface central point at each node are obtained. The electrode motion path coordinates were fitting optimized based on the non-uniform rational B-splines (NURBS) curves. The experimental investigation of electrode motion path verification is carried out, and the result shows that the error of blade profile is ±0.08 mm, which meets the design requirements. The results show that the present design method of electrode structure and its motion path is reasonable and effective for the closed integral impeller of EDM, and can be used as a general solution for this kind of problem.
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Key words:
- closed blisk /
- EDM /
- electrode /
- motion path search /
- optimization
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表 1 精加工实验参数
脉冲宽度ton /μs 脉冲间隙toff /μs 峰值电流Ip /A 伺服电压U/V 放电极性 工作液 40~60 20~30 4~6 50 正极性加工 火花专用液 
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表 2 叶间通道型面误差
测点位置 型面误差/mm 通道b(未优化轨迹) 通道f(优化后轨迹) z=15 叶盆 0.110 0.082 叶背 0.134 0.079 z=30 叶盆 0.088 0.071 叶背 0.080 0.050 z=45 叶盆 0.045 0.024 叶背 0.032 0.020 z=60 叶盆 0.015 0.015 叶背 0.018 0.015
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