Dynamic Simulation Of The Linear Friction Welding Process Of Blisk

The manufacture of the blade-and-disk (blisk) is a key technique to develop high thrust-weight ratio aero engines. Linear friction welding (LFW) is one of the most advanced methods to produce blisk. With the financial support from the aviation science foundation (The simulation and virtual manufacturing of linear friction welding process of the blisk) , the dynamic simulation of linear friction welding process of the blisk has been researched, the correlative parts such as technology and structure have been investigated in this article.Based on the parameters analysis of two kinds of blisks-turbine and supercharger, which represent two kinds of blisks with similar and dissimilar material between blade and disk, structures of linear friction welds are designed. The supercharger disk is designed to be boss structure with a welding technical boss on the root of the corresponding blade; while the turbine disk is grooved and left two side faces on the blade root as welding surfaces. According to the heat-generated expressions and the relative material characters, the friction welding parameters of this two kinds of blisks are achieved. The clamps of the blade are designed according to the structure of blisks, the force is analyzed and the strength is checked. After electing a 3D animation dynamic simulation scheme as technical path, 3Dentity models are established by 3D mechanical design software SolidWorks, and virtual assemble and collision detection have been done. 3D dynamic simulation of linear friction welding process is done by 3D animation fabricate software 3DS MAX. According to the simulation results, the way of vibration, the technologies of linear friction welding of the blisk, mechanical process after welding and nondestructive detection method have been chosen. The effects of technological parameters to linear friction welding process are analyzed .To remove the flash and boss after welding, it is suggested to use five coordinates numerical control machine to elaborate supercharge blisk, and Wire Cut Electrical Discharge Machining or Electrical Discharge Machining to elaborate the flash of the turbine blisk. It is advised to use ultrasonic detection to test inner defects and osmosis testing to surface defects after welding.The research results establish foundation to the following design of linear friction welder.