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1、摘 要本文通过对叶片中汽轮机低压缸二级动锁叶片机械加工工艺及其型线数控加工工艺的分析，并针对数控铣加工工艺环节作出详细分析，利用VERICUT进行仿真，最后在国产四轴机床进行加工，并用三坐标检测仪进行检验，达到加工要求。总结出低压缸二级动锁叶片机械加工和数控加工过程中容易出现的加工质量问题及对下道工序的影响。通过生产实践证明，利用本文中的加工工艺和数控加工程序对此产品进行生产加工，产品的加工质量得到很好的保证，同时加工效率得到了很大的提高，适用于低压缸动锁叶片的批量生产，对其他航空叶片，风电叶片提供一定借鉴方法。在加工工艺中，充分考虑数控加工和普通机床加工的加工成本差异，利用普通铣床粗加工效率
2、高，设备使用成本相对较低的特点，尽可能将产品中排除余量的工序安排在其上面加工，使其加工成本得到降低，现已广泛用于实际生产中。关键词：叶根；叶冠；出汽边；进汽边；计算机辅助编程（CAM）；UG；VERICUT；三坐标。AbstractMoving through the low pressure cylinder lock blade machining process and the form of line process analysis of NC and CNC milling process for a detailed analysis of aspects，summed up t
3、he moving LP cylinder lock blade machining and CNC machining process easier processing quality problems arise and the impact on the next working procedure. Proved by the production，processing technology used in this article, and NC machining program for this product production and processing，product
4、 processing to ensure good quality，and processing efficiency has been greatly improved for moving low-pressure cylinder lock blade mass production，in processing technology，the full account of CNC machining and general machining differences in processing costs，the use of ordinary milling roughing, hi
5、gh efficiency，relatively low-cost device characteristics，as far as possible to exclude the products of the process margin arrangements the above processing，processing costs are reduced so that it is now widely used in practice. Key words： leaves root； leaf crown；the steam side； into the steam side；c
6、omputer aided programming (CAM)；UG.目 录一、低压缸动锁叶片加工工艺分析以及工序制定。1（一）低压缸动锁叶片加工工艺分析。1（二）低压缸动锁叶片加工工序制定。2二、低压缸动锁叶片型线数控铣加工工艺分析及制定。12（一）低压缸动锁叶片型线数控铣加工工艺分析。12（二）低压缸动锁叶片型线数控铣加工工艺制定。12三、VERICUT仿真检验33四、三坐标型线检测：36结束语39参考文献40致谢41汽轮机中低压缸动锁叶片是将高压高温气流通过进汽侧出汽侧带动汽轮转动，是机汽轮机设备中的核心部件，它的加工质量的好坏直接影响汽轮机工作效率，特别是其型线的加工精度要求很高，叶片
7、型线的实际几何形状与设计尺寸越逼近，则汽轮机能量转换过程中的能耗就越少，其工作就越稳定。在当今环保理念的倡导下，节约能源是全世界企业的责任，所以研究压缸锁叶片的加工工艺和方法，对汽轮机的发展有很大的促进作用。一、低压缸动锁叶片加工工艺分析以及工序制定。（一）低压缸动锁叶片加工工艺分析。低压缸动锁叶片在工作中承受高温高压，所以其材料为1Cr12Mo-5,其特性防腐，且高强度，但其可铸造性很差，所以毛坯为锻造件。根据零件图1-1所示分析，为防止型线表面被划伤，变形，应型线数控加工放在其最后一个工序。为了保证叶片型线与叶根，叶冠面的位置公差要求，应将叶根，叶冠，中心孔的加工放在叶片型线加工之前。 图
8、1-1 零件示意图（二）低压缸动锁叶片加工工序制定。 根据以上工艺分析，将其制定成可实施的加工工艺文件如下：图号X300E-213002A004名称低压缸动锁叶片材料1Cr12Mo-5工序号工序内容机床工艺装备5铣 1，铣一平差要求面，表面见光即可，尺寸不小于50mm,保证图示形位公差要求： 图1-2 工序加工示意图2，铣一侧面，该侧面见光即可，尺寸不小于74.5mm，保证图示形位公差要求： 图1-3 工序加工示意图X6132X6132平口虎钳200刀口形直尺游标卡尺0125mm可转位面铣刀平口虎钳200刀口形直尺游标卡尺0125mm图号X300E-213002A004名称低压缸动锁叶片材料1
9、Cr12Mo-5工序号工序内容机床工艺装备510铣 3，铣一侧面，控制尺寸71.4mm，保证图示形位公差要求： 图1-4工序加工示意图 磨 磨两侧面Ra1.6控制尺寸71.2，保证图示形位公差要求： 图1-5 工序加工示意图X6132MT132平口虎钳200刀口形直尺游标卡尺可转位面铣刀外径千分尺百分表图号X300E-213002A004名称低压缸动锁叶片材料1Cr12Mo-5工序号工序内容机床工艺装备1520粗铣 粗铣长度方向两端面控制尺寸232，保证图示形位公差要求： 图1-6 工序加工示意图铣 铣另一表面及修第一平面，控制尺寸47.6，Ra3.2,保证图示形位公差要求： 图1-7 工序加
10、工示意图X6132X6132平口虎钳200刀口形直尺游标卡尺可转位面铣刀90度角尺平口虎钳200刀口形直尺游标卡尺0125mm可转位面铣刀90度角百分表03/0.01图号X300E-213002A004名称低压缸动锁叶片材料1Cr12Mo-5工序号工序内容机床工艺装备2530精铣 精铣长度方向两端面，控制尺寸231，保证图示形位公差要求： 图1-8 工序加工示意图打中心孔 打中心孔A2.5/6.3图1-9 工序加工示意图X6132X6132平口虎钳200刀口形直尺游标卡尺0125mm可转位面铣刀90度角中心钻A2.5/6.3游标卡尺0125mm图号X300E-213002A004名称低压缸动锁
11、叶片材料1Cr12Mo-5工序号工序内容机床工艺装3540刻标识 在图示位置区域刻标识，刻标识面即为叶根的出气边。1.注意中心孔尺寸28.2mm与标识面的位置关系2.标识刻的具体技术要求详见文件，见下图图1-10 工序加工示意图倒角1.背弧出气边倒角注意区分进出气边，刻有标识一侧为叶根出气边。图1-11工序加工示意图2.背弧进气边倒角，注意区分进出气边，刻有标识一侧为叶根出气边。 图1-12工序加工示意图X6132X6132X6132平口虎钳200刀口形直尺游标卡尺0125mm可转位面铣刀90度角尺回转虎钳万能角度尺0320/2游标卡尺0125mm回转虎钳万能角度尺0320/2游标卡尺0125
12、mm号X300E-213002A004名称低压缸动锁叶片材料1Cr12Mo-5工序号工序内容机床工艺装备4550铣1.粗铣背径向面1度417，检测用正弦规3.74块规，保证图示形位公差要求。2.粗精铣背径向面叶冠装配面，且应保证图示形位公差要求：注意区分进出气边，刻有标识一侧为叶根出汽边图1-13工序加工示意图 粗铣1.粗铣内径向面叶冠装配面，单边留1mm精铣余量，R3.15处留3mm精加工余量。注意区分近出气边，刻有标识一侧为叶根出气边 图1-14 工序加工示意图X6132X6132平口虎钳200刀口形直尺游标卡尺0125mm可转位面铣刀90度角尺精密虎钳正弦规200百分表90度角尺0320
13、/2游标卡尺0125mm平行规R1R6.5图号X300E-213002A004名称低压缸动锁叶片材料1Cr12Mo-5工序号工序内容机床工艺装备5560数铣1.精铣内径向面14度17，检测用正弦规，7.48块规（正弦规200），保证图示形位公差要求。2.精铣内径向面叶冠装配面9.58，除95度角，R3.15处暂不加工外，其余及R1.5均加工附图，且应保证图示形位公差要求。图1-15 工序加工示意图铣1.精铣内径向面，叶冠装配面，9.58处，95角 R3.15均附图。 图1-16 工序加工示意图CK650X6132平口虎钳200刀口形直尺游标卡尺0125mm可转位面铣刀90度角尺精密虎钳正弦规2
14、00百分表90度角尺0320/2游标卡尺0125mm平行规R1R6.5图号X300E-213002A004名称低压缸动锁叶片材料1Cr12Mo-5工序号工序内容机床工艺装备6570线切割线切割叶根型线，首件需经过半精铣加工合格后方可批量生产。铣型线粗铣汽道型线。加工时用径向面定位，首件须经三坐标检验合格后方可继续加工。注意附图中技术要求，图1-17 工序加工示意图HCKX3200BV100平口虎钳200刀口形直尺游标卡尺0125mm可转位面铣刀90度角尺游标卡尺0125mm半径规R1R6游标高度尺R500/0.02截面P+-WREDmax+-0.38bR出R进CC23.2445.4913.24
15、+-0.2212.381.80.310.88EE22.2843.6215.51+-0.2111.991.80.310.89DD20.1440.1419.78+-0.0211.31.740.310.84截面QQQCC5.956.26.95EE6.366.617.36DD7.127.378.121.工内容,汽道型面,内背弧圆角2.细为精铣单面留0.50.8的加工余量。3.截面光滑过度，不允许有明显凹凸，型线波峰波谷公差小于0.054.线与样板间漏管间隙，内背弧漏光不大于0.055.见产品图，型线图及工艺规程。6.须经三坐标检验，合格后方可继续加工。7.过程中，按1/10三坐标检验,其余用型线样板检
16、查.8.时用内径向面定位.二、低压缸动锁叶片型线数控铣加工工艺分析及制定。（一）低压缸动锁叶片型线数控铣加工工艺分析。根据其机械加工工艺中工序图可知，在数控铣上的叶片毛坯基本是长方体，不能直接采用四轴联动进行加工，先用直径为25R5的牛鼻刀进行粗加工，采用平行与X轴走刀方式，再进行半精加工，精加工以及清根加工。（二）低压缸动锁叶片型线数控铣加工工艺制定。根据加工要求，以及工厂实际设备，刀具条件，将其加工工艺制定如下：图号X300E-213002A004名称低压缸动锁叶片材料1Cr12Mo-5工序号工步内容刀具名称直径（mm）转速，进给量机床70铣型线5粗加工型线圆鼻刀25R51400R/min
17、,1000mm/minBV100根据加工要求，我们选择UG软件的的行腔加工策略，设置参数如下：生的刀具轨迹如图：图2-2 粗铣工刀具路径示意图加工程序：N0010 G40 G17 G90 G71N0020 G91 G28 Z0.0N0030 T01 M06N0040 G00 G90 X-229.452 Y-92.13 A352.199 S2200 M03N0050 G43 Z46.315 H00N0060 Y-92.131N0070 Z-3.685N0080 G01 X-229.441 Y-91.759 Z-4.594 F3000. M08N0090 X-229.427 Y-91.318 Z-
18、5.47N0100 X-229.412 Y-90.809 Z-6.31N0110 X-229.395 Y-90.236 Z-7.106N0120 X-229.375 Y-89.602 Z-7.855N0130 X-229.354 Y-88.912 Z-8.553N0140 X-229.332 Y-88.168 Z-9.193N0150 X-229.308 Y-87.377 Z-9.774N0160 X-229.283 Y-86.543 Z-10.29N0170 X-229.256 Y-85.671 Z-10.74N0180 X-229.229 Y-84.767 Z-11.12N0190 X-2
19、29.201 Y-83.835 Z-11.427N0200 X-229.172 Y-82.882 Z-11.661N0210 X-229.142 Y-81.914 Z-11.819N0220 X-229.113 Y-80.936 Z-11.9N0230 X-229.083 Y-79.955 Z-11.904N0240 X-229.053 Y-78.977 Z-11.832N0250 X-229.024 Y-78.007 Z-11.683N0260 X-228.995 Y-77.052 Z-11.458N0270 X-228.967 Y-76.118 Z-11.159N0280 X-228.83
20、1 Y-71.61 Z-9.583 N0290 X-228.664 Y-67.105 Z-8.005 N0300 X-228.466 Y-62.603 Z-6.425 N0310 X-228.237 Y-58.103 Z-4.846 N0320 X-227.978 Y-53.605 Z-3.265 N0330 X-227.688 Y-49.111 Z-1.684 N0340 X-227.368 Y-44.619 Z-.102 N0350 X-227.016 Y-40.13 Z1.479 N0360 Y-40.129 Z1.488 N0370 X-226.769 Y-37.957 Z2.021
21、N0380 X-226.523 Y-35.789 Z2.572 N0390 X-226.277 Y-33.627 Z3.14 N0400 X-226.031 Y-31.468 Z3.725 N0410 X-225.786 Y-29.315 Z4.327 N0420 X-225.541 Y-27.166 Z4.946 N0430 X-225.296 Y-25.022 Z5.582 N0440 X-225.048 Y-22.882 Z6.236 N0450 X-225.049 Y-22.874 Z6.248 N0460 X-224.972 Y-22.485 Z6.328 N0470 X-224.8
22、99 Y-22.097 Z6.409 N0480 X-224.825 Y-21.71 Z6.492 N0490 X-224.751 Y-21.324 Z6.577 N0500 X-224.678 Y-20.938 Z6.663 N0510 X-224.604 Y-20.552 Z6.752 N0520 X-224.531 Y-20.166 Z6.842 N0530 X-224.458 Y-19.781 Z6.933 N0540 X-224.385 Y-19.397 Z7.027 N0550 X-224.312 Y-19.013 Z7.123 N0560 X-224.239 Y-18.629 Z
23、7.22 N0570 X-224.166 Y-18.246 Z7.319 N0580 X-224.093 Y-17.863 Z7.42 N0590 X-224.02 Y-17.481 Z7.523 N0600 X-223.948 Y-17.099 Z7.627 N0610 X-223.875 Y-16.717 Z7.733 N0620 X-223.803 Y-16.337 Z7.841 N0630 X-223.731 Y-15.956 Z7.951 N0640 X-223.658 Y-15.576 Z8.063 N0650 X-223.586 Y-15.197 Z8.176 N0660 X-2
24、23.514 Y-14.818 Z8.291 N0670 X-223.442 Y-14.44 Z8.408 N0680 X-223.37 Y-14.062 Z8.526 N0690 X-223.299 Y-13.685 Z8.646 N0700 X-223.227 Y-13.309 Z8.769 N0710 X-223.155 Y-12.933 Z8.892 N0720 X-223.084 Y-12.557 Z9.018 N0730 X-223.012 Y-12.183 Z9.145 N0740 X-222.941 Y-11.808 Z9.274 N0750 X-222.87 Y-11.435
25、 Z9.405 N0760 X-222.798 Y-11.062 Z9.538 N0770 X-222.725 Y-10.688 Z9.672 N0780 X-222.726 Y-10.682 Z9.674 N0790 X-222.672 Y-10.51 Z9.74 N0800 X-222.619 Y-10.338 Z9.807 N0810 X-222.567 Y-10.167 Z9.875 N0820 X-222.514 Y-9.997 Z9.944 N0830 X-222.461 Y-9.827 Z10.014 N0840 X-222.408 Y-9.657 Z10.085 N0850 X
26、-222.355 Y-9.488 Z10.156 N0860 X-222.302 Y-9.319 Z10.229 N0870 X-222.249 Y-9.151 Z10.302 N0880 X-222.196 Y-8.983 Z10.376 N0890 X-222.142 Y-8.815 Z10.452 N0900 X-222.089 Y-8.648 Z10.527 N0910 X-222.036 Y-8.481 Z10.604 N0920 X-221.982 Y-8.315 Z10.682 N0930 X-221.929 Y-8.15 Z10.761 N0940 X-221.875 Y-7.
27、984 Z10.84 N0950 X-221.822 Y-7.82 Z10.92 N0960 X-221.768 Y-7.656 Z11.001 N0970 X-221.715 Y-7.492 Z11.083 N0980 X-221.661 Y-7.329 Z11.166 .图号X300E-213002A004名称低压缸动锁叶片材料1Cr12Mo-5工序号工步内容刀具名称直径（mm）转速，进给量机床70 铣型线10半精加工型线圆鼻刀25R5220R/min,1200mm/minBV100根据工艺要求，我们选择UG加工中的可变轴轮廓加工，设置参数见面如下：图1-2半精加工刀具路径示意图加工程序N
28、0010 G40 G17 G90 G71N0020 G91 G28 Z0.0N0030 T01 M06N0040 G00 G90 X-229.452 Y-92.13 A352.199 S2200 M03N0050 G43 Z46.315 H01N1090 X-221.07 Y-5.567 Z12.133 A14.968N1100 X-221.016 Y-5.41 Z12.226 A15.293N1110 X-220.962 Y-5.253 Z12.319 A15.617N1120 X-220.908 Y-5.098 Z12.414 A15.942N1130 X-220.854 Y-4.942
29、Z12.509 A16.267N1140 X-220.801 Y-4.788 Z12.605 A16.591N1150 X-220.747 Y-4.633 Z12.702 A16.916N1160 X-220.693 Y-4.48 Z12.799 A17.241N1170 X-220.639 Y-4.327 Z12.898 A17.565N1180 X-220.585 Y-4.174 Z12.997 A17.89N1190 X-220.531 Y-4.023 Z13.097 A18.214N1200 X-220.478 Y-3.871 Z13.198 A18.538N1210 X-220.42
30、4 Y-3.721 Z13.3 A18.863N1220 X-220.37 Y-3.571 Z13.402 A19.187N1230 X-220.316 Y-3.421 Z13.505 A19.511N1240 X-220.262 Y-3.272 Z13.609 A19.835N1250 X-220.209 Y-3.124 Z13.714 A20.159N1260 X-220.155 Y-2.976 Z13.82 A20.483N1270 X-220.101 Y-2.829 Z13.926 A20.806N1280 X-220.047 Y-2.683 Z14.033 A21.13N1290 X
31、-219.994 Y-2.537 Z14.141 A21.454N1300 X-219.94 Y-2.392 Z14.249 A21.778N1310 X-219.886 Y-2.247 Z14.358 A22.101N1320 X-219.833 Y-2.104 Z14.468 A22.425N1330 X-219.779 Y-1.961 Z14.579 A22.748N1340 X-219.725 Y-1.818 Z14.691 A23.072N1350 X-219.672 Y-1.676 Z14.803 A23.395N1360 X-219.618 Y-1.535 Z14.916 A23
32、.718N1370 X-219.564 Y-1.394 Z15.03 A24.041N1380 X-219.511 Y-1.254 Z15.144 A24.364N1390 X-219.457 Y-1.115 Z15.259 A24.687N1400 X-219.404 Y-.976 Z15.375 A25.01N1410 X-219.35 Y-.839 Z15.491 A25.333N1420 X-219.3 Y-.703 Z15.609 A25.656N1430 X-219.299 Y-.716 Z15.613 A25.696N1440 X-219.266 Y-.667 Z15.694 A
33、25.981N1450 X-219.22 Y-.606 Z15.8 A26.366N1460 X-219.164 Y-.534 Z15.933 A26.848N1470 X-219.119 Y-.478 Z16.042 A27.244N1480 X-219.074 Y-.423 Z16.151 A27.636N1490 X-219.026 Y-.364 Z16.269 A28.063N1500 X-218.981 Y-.31 Z16.382 A28.469N1510 X-218.937 Y-.259 Z16.491 A28.862N1520 X-218.891 Y-.205 Z16.607 A
34、29.277N1530 X-218.846 Y-.153 Z16.722 A29.69N1540 X-218.803 Y-.104 Z16.833 A30.082N1550 X-218.758 Y-.054 Z16.948 A30.491N1560 X-218.713 Y-.004 Z17.065 A30.907N1570 X-218.671 Y.042 Z17.176 A31.3N1580 X-218.628 Y.089 Z17.291 A31.705N1590 X-218.583 Y.137 Z17.41 A32.123N1600 X-218.541 Y.181 Z17.522 A32.5
35、16N1610 X-218.499 Y.225 Z17.638 A32.918N1620 X-218.456 Y.269 Z17.756 A33.332N1630 X-218.414 Y.311 Z17.871 A33.73N1640 X-218.372 Y.353 Z17.986 A34.131N1650 X-218.33 Y.394 Z18.105 A34.541N1660 X-218.289 Y.434 Z18.221 A34.943N1670 X-218.248 Y.473 Z18.337 A35.343N1680 X-218.207 Y.512 Z18.456 A35.75N1690
36、 X-218.166 Y.55 Z18.574 A36.155N1700 X-218.125 Y.586 Z18.691 A36.553N1710 X-218.085 Y.622 Z18.81 A36.958N1720 X-218.044 Y.657 Z18.929 A37.366N1730 X-218.005 Y.691 Z19.046 A37.763N1740 X-217.965 Y.724 Z19.165 A38.166N1750 X-217.925 Y.757 Z19.286 A38.576N1760 X-217.886 Y.788 Z19.404 A38.972N1770 X-217
37、.847 Y.818 Z19.523 A39.374N1780 X-217.808 Y.849 Z19.644 A39.781N1790 X-217.77 Y.877 Z19.763 A40.18N1800 X-217.731 Y.905 Z19.882 A40.58N1810 X-217.693 Y.933 Z20.003 A40.986N1820 X-217.655 Y.959 Z20.124 A41.387N1830 X-217.617 Y.984 Z20.243 A41.786N1840 X-217.579 Y1.009 Z20.365 A42.19N1850 X-217.542 Y1
38、.033 Z20.486 A42.592N1860 X-217.505 Y1.056 Z20.606 A42.99N1870 X-217.468 Y1.078 Z20.727 A43.393N1880 X-217.431 Y1.099 Z20.849 A43.797N1890 X-217.395 Y1.119 Z20.969 A44.194N1900 X-217.358 Y1.139 Z21.091 A44.595N1910 X-217.322 Y1.157 Z21.214 A45.N1920 X-217.286 Y1.175 Z21.334 A45.396N1930 X-217.25 Y1.
39、192 Z21.456 A45.778图号X300E-213002A004名称低压缸动锁叶片材料1Cr12Mo-5工序号工步内容刀具名称直径（mm）转速，进给量机床70 铣型线15,精加工型线球头铣刀20220R/min,1000mm/minBV100根据加工要求，更换刀具，跟开粗同样设置，然后加密步距即可1-3精加工型线刀具路径示意图加工程序N010 G40 G17 G90 G71N0020 G91 G28 Z0.0N0030 T02 M06N0040 G00 G90 X-229.452 Y-92.13 A352.199 S2200 M03N0050 G43 Z46.315 H02N1090
40、 X-221.07 Y-5.567 Z12.133 A14.968N2190 X-216.394 Y1.315 Z24.644 A56.188N2200 X-216.364 Y1.308 Z24.767 A56.585N2210 X-216.335 Y1.3 Z24.89 A56.985N2220 X-216.306 Y1.291 Z25.013 A57.383N2230 X-216.277 Y1.281 Z25.135 A57.779N2240 X-216.248 Y1.271 Z25.258 A58.179N2250 X-216.22 Y1.259 Z25.381 A58.577N2260
41、 X-216.192 Y1.246 Z25.503 A58.974N2270 X-216.164 Y1.233 Z25.626 A59.373N2280 X-216.136 Y1.219 Z25.749 A59.771N2290 X-216.109 Y1.204 Z25.871 A60.167N2300 X-216.082 Y1.188 Z25.993 A60.565N2310 X-216.055 Y1.171 Z26.115 A60.964N2320 X-216.029 Y1.154 Z26.237 A61.36N2330 X-216.003 Y1.135 Z26.359 A61.757N2340 X-215.976 Y1.115 Z26.482 A62.156N2350 X-215.951 Y1.095 Z26.603 A62.553N2360 X-215.925 Y1.074
