| The blisk is one of the important parts on the aero-engine and other products, its main processing methods include high speed cutting, electrochemical machining, connecting method, EDM, especially the electrochemical machining will become one of the main processing method of the blisk because of its unique advantages. In the manufacturing process of blisk, it often needs to measure its blade repeatedly and adjusts testing program according to the results of the measurement. Offline measurement was adopted in the past, but each offline measurement needed to take blisk down from the machine tool, there is a little troubles in fixture adjustment and tool setting, both time-consuming and laborious, which prolonged the trial production of the parts. Therefore, a set of online measuring system for electrochemical machining of the blisk was developed, which had mainly studied the way of building the system, measuring method, data processing and error analysis, etc, and realized blisk’s online measurement, data processing and results output, also improved the efficiency of part measurement.Firstly, the blisk’s structure and method of online measuring system was studied. And the online measuring system was composed of controller, measuring system, data processing, analysis software and wired and wireless communication module.The driver of the measurement system with the aid of the ECM machining tool’s original ac digital servo drive system, had developed the corresponding measuring driver software by using functions provided by motion controller manufacturers based on its hardware, and each motor shaft drive of machine tool was realized, thus that the structure of measurement system was simplified. The RMP60was choosed as the machine tool measuring probe, which was producted by RENISHAW British company, and the measured data through the wireless network was sent to the receiver, and then through the wired network to the computer, finally the whole data processing and machining error analysis was completed.Secondly, the method of measurement and data processing was researched in blisk’s measurement system. The measuring path had been planned according to the characteristics of the blisk’s blade, and the blisk’s measuring driver software was developed on the software platform of UG NX8.5by using Visual C++, the motion path and program measured by the software was automatically generated by machine tools and run the machine, at the same time the RMP60probe started to measure and extract data, then the extracted data was ready for data processing in computer, and the tools of NURBS spline in UG was used for the blade’s converse modeling, and the model used the function provided by UG to analyze the error of the blade, thus the blisk’s drive, measurement and data analysis was completed.Finally, the development of the blisk’s online measuring system was applied. In the electrochemical manufacturing process of a type of blisk, the blisk’s online measurement and error analysis has been done. The measuring results revealed that the online measurement system could implement modeling data matching, dimension driving of motorial axis and the measuring drive of probe, and the data was imported into software for further interpolation algorithm, directly generated measuring model of blade, through the software analysis, the dimensional tolerance both directions of blade are0.0254mm, and the angle tolerance is0.5°, but the tolerance except both directions of blade is slightly different, its dimensional tolerance is0.0255mm and angle tolerance is0.51°. |
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