Research and Application of Multi-Axis Wire-Cutting Technology for Integral Blisk
XU Weihong 1 , SONG Weiwei 2 , GAO Sufang 3
1. AECC Nanjing Light Aviation Power Co., Ltd., Nanjing 210000, China;
2. Aviation Military Representative Office of the Army Equipment Department in Shanghai, Shanghai 200233, China;
3. Beijing Hanfei Aero Technology Co., Ltd., Beijing 101307, China
Abstract：Integral blisk is the key part of aero-engine with slender blade, large torque angle, large erosion removal quantity between blade channels, weak structure strength. It is difficult to manufacture due to its high-temperature alloy material. The commonly-used milling machining method for blade channels has many short-comings, such as, low machining efficiency, high deformation rate, and low machining quality of parts. In order to increase manufacturing efficiency and quality, and to decrease manufacturing cost of the blade channels of integral blisk, we analyzed the characteristic of the blade channel structure and machining technique, and proposed a new machining technique including wire-cut, electrical discharge machining (EDM) forming, and fine milling, which is a total novel technology scheme with characteristics of micro-stress, low cost, high quality, in brief, electro-electro-milling technology scheme. We also designed multi-axis wire-cutting technique and special wiring devices used for inside-and-outside outline cutting. The problems such as low quality, low efficiency have been resolved through normalizing process parameters in clamping and positioning, electrical parameters, cutting path. Finally, the effectiveness (increasing the machining quality and efficiency, lowering the machining costs) of the proposed technology scheme has been verified through typical parts machining.
2022, 
