【摘要】 针对现今航空发动机叶片气膜孔传统电火花加工方法存在的生产周期长,ND:YAG激光加工方法加工质量较差的问题,提出基于辅助电极法的气膜孔电火花一次加工成形技术。针对该方法开展了4项关键技术研究,包括热障涂层高温合金数控系统、放电状态辨识系统、脉冲电源和基于模糊控制的伺服控制系统。基于上述技术,研制热障涂层高温合金气膜孔电火花加工控制系统,以实现加工过程中间隙放电状态的准确调节,提高加工效率与加工质量。以φ0.5mm气膜孔加工为例,与常规电火花加工控制系统进行对比试验,验证该技术有效性,研制试验表明,采用自行研制热障涂层高温合金电火花加工控制系统,可提高加工效率达110%,且孔口无微孔隙,交界面无分层微裂纹缺陷,验证试验表明,该系统可有效提高加工效率与加工质量。更多还原

【Abstract】 Aiming at the problem of long production cycle of cooling holes in the aero-engine blades with EDM method and the poor processing quality of the ND:YAG laser drilling, one step EDM of cooling holes was proposed based on assisting method. Due to significant difference in gap discharge state between ceramic coatings and superalloys, current EDM control systems were able to achieve a stable and accurate control, which cannot make a compromise on processing efficiency and quality. Therefore, Key techniques for EDM of cooling holes were studied, including discharge state identification method of thermal barrier coated-superalloy, pulse power supply and servo control strategy based on fuzzy control. Based on the above technology, the EDM control system for drilling thermal barrier coated-superalloys was developed. The comparison experiments show that compared with the conventional EDM control system, the self-developed system can improve processing efficiency by 110%, and can obtain better machining quality.更多还原