面向线接触加工的叶片曲面几何建模与容差设计

项目名称： 面向线接触加工的叶片曲面几何建模与容差设计

项目编号： No.51475302

项目类型： 面上项目

立项/批准年度： 2015

项目学科： 机械、仪表工业

项目作者： 毕庆贞

作者单位： 上海交通大学

项目金额： 80万元

中文摘要： 整体叶轮是决定叶轮机械工作性能的关键零件，其叶片曲面五轴线接触加工具有高切削带宽、高表面质量和高一致性的优势，成为提升叶轮制造水平的重要方法。为保证工作性能前提下提升整体叶轮的线接触加工率，本项目拟将叶片设计与制造统一到双参数球族包络理论的框架下，研究中弧面-厚度分布曲面的双参数球族包络模型与叶片曲面三维设计方法，基于刀具包络面和叶片曲面的双参数球族包络模型研究刀具轴迹面控制参数调整对叶片设计参数的影响规律，实现面向整体叶轮线接触加工的三维设计；同时研究线接触加工叶轮误差的统计学模型，研究主要模态误差对气动效率和几何失谐的影响规律，将这两项性能对加工误差的敏感度引入线接触加工领域，研究面向性能的的容差设计和质量评价方法。最后，开发出面向线接触加工的叶轮设计、轨迹规划和质量评价软件，在航空发动机和汽车涡轮增压器中推广应用，为叶片曲面线接触加工提供新方法。

中文关键词： 复杂曲面；数控加工；数字化制造；数字化设计与制造；逆向工程

英文摘要： The integrated impeller is the key component to determine the performance of turbo-machinery. Because large machining width can be obtained, as well as better surface quality and uniformity, five axis flank milling becomes the primary way to improve the manufacturing level of integrated impeller. A unified theoretical framework will be developed for designing and manufacturing of impellers based on the sphere-swept envelope theory. This work will help to improve the rate of line contact machining of impellers while guaranteeing the perforamce. This research will focus on: 1)develop the three dimensional design method for blade surfaces represented by camber surface-thickness based on sphere-swept envelope theory; 2)establish the quantitatively relationship of the change of the geometric parameters of the impeller under the deformation of the tool axis trajectory surface based on the sphere-swept models of the cutter and blade surface, and achieve a method to design a flank millable blade surface; 3)develop the model of principle error on aerodynamic performance and geometric mistuning of impellers based on the probabilistic model of impellers due to line contact manufacturing error; 4)develop the performance-based tolerance design method and quality evaluation method by integrating the sensitivity analysis of machining error on impeller performance. Finally, a software with the functions of flank millable blade surface design, tool path generation and quality evaluation will be developed, and the achievements of this project will be used in aeroengines and automotive turbochargers, formulating a new method of flank millable surface and tolerance design.

英文关键词： Complicated surface;NC machining;Digital manufacturing;Digital design and manufacturing;Reverse engineering