The development of aircraft structures is under tremendous pressure, the most prominent of which is the standard requirements for legislation to increase the carbon dioxide emissions of aircraft, and the rapid increase in market attention to this standard. Therefore, the aircraft engine has naturally become the focus of the industry development, while ensuring a lower speed of fuel consumption, but also to ensure faster speed of the advancement value. This puts higher demands on the components used in the engine, such as the need to select special materials with high bearing capacity. So how can a machine guarantee the speed, accuracy and integrity of the process when processing these materials? EMAG experts here give an optimal solution: EMAG electrochemical machining technology, mechanical cutting technology can no longer be considered when making decisions. It can be said that EMAG precision electrochemical processing technology has brought new vitality to the development of technology in the field of aero-engine manufacturing.
There is an important interrelationship in the aero engine manufacturing process, that is, the higher the temperature generated by the engine, the higher the efficiency. That is to say, the higher the engine temperature, the farther the aircraft can fly, while consuming relatively little fuel. This corresponds to the material used inside the aeroengine, which means that extremely wear-resistant materials that perform better under pressure must be selected. But the choice of good materials is only "half a success", because at the same time, many components will become more complex and require a highly sophisticated process to complete. Therefore, the aero engine department wants to achieve the goal of reducing carbon dioxide emissions and fuel consumption by 20% in the next decade, and it is necessary to complete the above. I believe this is the only way.
EMAG CNC precision electrolytic machining PECM technology - an integral part of the aero engine innovation technology ECM (PECM)
The overall leaf disc appears to meet the needs of the market. Compared with the conventional rotor blades and the disc-separated assembled leaf discs, the impeller edge load is reduced and the weight is reduced due to the reduction of the assembly parts such as the boring head and the gutter in the conventional connection. Up to 30%, while reducing the loss of steam flow, that is, reducing power consumption, thereby improving aerodynamic efficiency and significantly increasing power, helping to reduce fuel consumption and exhaust emissions. The history of its development was first applied to the end of high pressure compressors and commercial compressors. It is the most innovative and challenging part of modern gas turbine engines.
Figure 1: Overall leaf disk simulation
1. Variable stator blade 2. Compressor impeller 3. Combustion chamber 4. Power turbine
5. Gas turbine 6. Compressor 7. Power output drive shaft
Precision electrochemical machining, the inevitable choice for the development of aero-engine manufacturing
Of course, this development process is a different process from the automotive field. This development of aircraft engines has a milestone historical significance for the aircraft industry. Today, the industry has reached a crossroads, and experts predict that in the next two decades, air traffic demand will increase at a rate of 5% per year. Airbus also said that the market demand for new engines in the aviation market will reach 7,600 units in the next ten years. This provides a huge opportunity for the development of the aviation industry, but it also puts new demands on the aero engine manufacturer. The new engine must constantly meet market demands and optimize its technical level and product quality.
For aero engine manufacturers, what kind of machining solution can be selected to efficiently and accurately produce this new energy-efficient engine component? EMAG Electrochemical Machining (ECM) and Precision Electrochemical Machining (PECM) technologies are arguably the best choice, although many developers and design engineers have not yet realized this. However, the use of this technology for the processing of high-strength alloys and similar materials, the complex parts, not only make the processing tool (here, the cathode consumption is basically negligible) to achieve the minimum degree of wear, and the surface of the processed parts has a more For superior quality, such as no burrs, (material intergranular structure) no microstructural changes. In contrast, the cutting process creates many problems, such as the temperature generated adversely affects the microstructure of the material; the tool used for machining high-strength materials has a short life; the high-feed machining process is cost-effective. However, it is impossible to process precise geometric shapes and so on. These problems undoubtedly indirectly promote the increasing demand for ECM technology in the aero-engine manufacturing industry. Since EMAG began researching this technology in 2009, it has provided a large number of equipment and technology for aero engine manufacturers, and is mainly used in the production and manufacture of core components for aircraft engines, such as high-precision nickel-based alloy materials for high-precision overall manufacture. Leaf discs, with dovetail slots, and individual blades.
EMAG's whole leaf disc precision electrolytic machining - technology for the future
The production and application of the whole leaf disc is obvious. The main reason for this trend is from civilian demand.
In the face of fierce market competition, independent and economical processes are the first choice, especially the tailor-made complete solution to shorten the routing path needs to be optimized to meet the needs of the market.
Overall leaf disc manufacturing technology
The overall processing technology of the whole leaf disc
·Efficient overall milling
·Multi-axis linkage CNC precision electrolysis: Due to the significant reduction in overall tool cost, electrolysis and precision electrolysis are developing into the best processing technology for the overall leaf disc of superalloy materials.
EMAG Electrochemical Co., Ltd. newly developed PO 900 BF precision multi-axis linkage high-frequency narrow pulse electrolytic machining center and a complete turnkey process - from the initial blade blank blank processing of the blade nesting (the initial selection of material removal) Blade twist angle and blade profile) until the final blade profile is formed into a complete process chain workpiece turnkey solution.
The EMAG PO 900 BF model is undergoing integral leaf disc processing
1. Efficient overall milling
Efficient overall milling technology refers to the roughing and finishing of blades in 5 or 6 axis machining centers. The typical process is cyclic staggered milling combined with high-performance equipment and high-pressure internal cooling for rough cutting. The most common practice for leaf disc finishing is ball milling, side milling and strip milling.
2. Multi-axis linkage CNC precision electrolysis: Due to the significant reduction in overall tool cost, electrolysis and precision electrolysis are developing into the best processing technology for the overall leaf disc of superalloy materials.
Multi-axis linkage CNC precision electrolytic machining technology combines the technical characteristics of multi-axis linkage computer numerical control and precision electrolytic machining (based on the principle of electrochemical anode dissolution to remove metal materials). The tool cathode has no loss, no macro cutting force, especially It is suitable for processing high-temperature alloys in the high-temperature zone at the end of the compressor or the high-flexible whole-leaf disc of the variable-section twisted blade of the titanium alloy.
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