Patent Description:
Integrally bladed rotors (IBR: Integrally Bladed Rotors), which are commonly referred to as BLISKs (BLISK: bladed-in disks) and in which a rotor disc and a blade are integrated to each other, have been proposed for use as fans and/or compressor rotors in gas turbine engines for aerial vehicle uses. This is because of the expectation that using an integrally bladed rotor leads to a great weight reduction of the engine, resulting in improved fuel efficiency. A known method for producing an integrally bladed rotor includes: producing a blade at a separate step and integrating the blade to a disc by a connection method similar to friction pressure welding. Another known production method is to cut a disc blank into an outer shape of a blade.

For example, <CIT> discloses a method associated with machining of a blade of an integrally bladed rotor having a complicated three-dimensional shape. In the method, point-contact milling is performed using a cutter having a hemispherical machining head. A complex shaped blade has a plate shape that is twisted about a radial direction axis and that is tapered from a base end portion toward a leading end portion of the blade. This blade is first subjected to rough milling, and then subjected to finish cutting by milling the depressed positive-pressure surface, the protruding negative-pressure surface, and a ring-shaped portion of the blade. In this respect, the both surfaces are subjected to milling in such a manner that the cutting edge of the cutter forms cutting strips that have equal widths and that are oriented in an air-flow direction in which air flows between the blades. Such blades are described as being low in aerodynamic loss.

When a blade is machined by milling into a complicated three-dimensional shape, chatter (vibration) and/or deformation are more likely to occur and become a serious problem at high-speed machining. In light of this, another method taken into consideration is to perform cutting using a turning chip. A machining control method referred to as "orbit boring" is known as a method of curved-surface machining performed by the above-described cutting. In this method, a tool spindle is caused to make a circular interpolation motion while the rotation of the tool spindle is controlled so that a turning tool is oriented in an arc radius direction.

For example, <CIT> describes such a method that includes performing speed clamp processing with respect to a control axis in orbit boring. Performing speed clamp processing is described as enabling a high speed motion of the control axis while preventing cutting load from fluctuating. Generally, if the speed of a radial movement is restricted, making an axial movement takes time, even though an orbiting motion can be continued. This elongates the time for the turning tool to make approaching and withdrawal motions. Also, at a high orbiting speed, the axes may exceed respective tolerance speeds, even if the radial direction speed is restricted. This may make it impossible to synchronize the axes, with the result that the machining can not be continued. In light of this fact, a measure proposed is to make speed clamp processing depend on a movement mode. Speed clamp processing is processing of controlling the control axes so that the feed rates of the control axes do not exceed respective tolerance feed rates.

Both <CIT> and <CIT> show a known method for producing an integrally bladed rotor, the integrally bladed rotor comprising a rotor disc and a three-dimensional and planar blade that is integral to the rotor disc and that has a positive-pressure surface and a negative-pressure surface as main surfaces, the method comprising: dividing a ridge of a front edge of the blade and a ridge of a rear edge of the blade into a predetermined number of ridge pieces, and based on a machining command, cutting the blade by circumferentially moving a cutting point around the blade, the cutting point corresponding to a position of the cutting edge.

In recent years, there has been a demand for a higher level of engine fuel efficiency toward engines such as gas turbine engines for use in aerial vehicles. In light of this demand and other considerations, there have been proposed integrally bladed rotors designed at an advanced level. This has caused a demand for a significantly high level of machining accuracy, especially for a high level of accuracy in machining thin blades.

It is thus the object of the present invention to provide a method for producing an integrally bladed rotor that highly accurately machines a blade by cutting; a program for cutting the blade; and an integrally bladed rotor obtainable by said method.

The object of the present invention is achieved by a method for producing an integrally bladed rotor having the features of claim <NUM>; a program for cutting a blade having the features of claim <NUM>; and an integrally bladed rotor having the features of claim <NUM> being obtainable by the method according to claim <NUM>.

In this invention, the cutting edge of a turning tool is moved, continuously at a uniform level of pressure, through a path interpolated by a closed curve that continues in a spiral shape. This ensures that a blade having a closed curve cross-section and superior in aerodynamic characteristics is machined highly accurately.

In this invention, the resulting blade has a closed curve cross-section and is superior in aerodynamic characteristics.

By referring to <FIG>, a method according to the present invention for producing an integrally bladed rotor will be described in detail.

As illustrated in <FIG>, an integrally bladed rotor <NUM> includes: a rotor disc <NUM>, which is a ring-shaped plate; and a plurality of the blades <NUM>, which are integral to the outer circumference of the integrally bladed rotor <NUM>. Each of the blades <NUM> is a three-dimensional plate having a positive-pressure surface <NUM> and a negative-pressure surface <NUM> as main surfaces.

As illustrated in <FIG>, each of the blades <NUM> of the integrally bladed rotor <NUM> is roughly machined in advance into a wing shape. Generally, the finishing of each blade <NUM> includes machining using a rotating tool such as an end mill. In this embodiment, however, the blade is cut by moving the cutting edge of a turning tool along the surfaces of the blade. Specifically, as indicated by the arrow illustrated in the figure of interest, the blade is cut by circumferentially moving a cutting edge <NUM> of a turning tool <NUM> around the blade <NUM> such that the cutting edge <NUM> starts from a point on the front edge <NUM> of the blade <NUM>; moves on the negative-pressure surface <NUM>, a rear edge <NUM>, and the positive-pressure surface <NUM> (or point on the front edge <NUM> of the blade <NUM> moves on the positive-pressure surface <NUM>, the rear edge <NUM>, and the negative-pressure surface <NUM>) in this order; and returns to the front edge <NUM>. More specifically, an imaginary closed curve C, which circumferentially moves around the blade <NUM> (see <FIG>), is prepared and a path R is defined by the closed curve C. The blade <NUM> is cut by moving the turning tool <NUM> relative to the blade <NUM> along the path R.

As illustrated in <FIG>, this cutting is performed by making a feed movement from a leading end portion toward a base end portion of the blade <NUM>. Specifically, a plurality of closed curves C, each of which is an imaginary curve (see <FIG>), are arranged in advance from the leading end portion toward the base end portion of the blade <NUM>. Then, the blade <NUM> is cut by making a feed movement along each of the closed curves C. This cutting is repeated by a number equal to the number of the closed curves C. That is, the cutting edge <NUM> is fed such that the cutting edge <NUM> moves from a start point on the closed curve C and makes a circumferential movement along the closed curve C, and that upon completion of one circumferential movement, the cutting edge <NUM> moves to a start point on the next closed curve. Thus, the cutting edge <NUM> moves spirally such that the cutting edge <NUM> moves to the adjoining closed curve every time the cutting edge <NUM> makes one circumferential movement. The path R is defined as a curve defined by this spiral movement. That is, the path R is a curve interpolated by making the closed curve C continue in a spiral shape. This ensures that the entirety of the positive-pressure surface <NUM>, the negative-pressure surface <NUM>, the front edge <NUM>, and the rear edge <NUM> of the blade <NUM> is cut.

This configuration will be further described by referring to <FIG>. After the blade <NUM> is cut by feeding the cutting edge <NUM> to make a circumferential movement along the closed curve C, a cutting point at a leading end portion of a chip <NUM> has moved along a curve defined by a corner portion between a post-cutting surface <NUM> and a step <NUM>, which is located between a pre-cutting surface <NUM> and the post-cutting surface <NUM>. This curve is defined as the path R. In this respect, the direction of extension of the cutting edge <NUM> of the chip <NUM>, which is mounted on a leading end portion of the turning tool <NUM>, is preferably parallel to a surface normal of the cutting point of the blade <NUM>. That is, the cutting point is moved on a curved surface smooth enough to ensure that a surface normal can be established at any portion of the curved surface. This configuration is preferable in that the occurrence of chatter is eliminated or minimized. In this case, the path R is a continuous curve smooth enough to ensure that a tangent can be established on every cutting point moving on the path R. Therefore, the path R is differentiable. The path R is obtained by applying a feed movement to a trajectory circumferentially drawn around the blade <NUM> along the closed curve C, and is made differentiable by interpolating the closed curve C as a differentiable curve. In this respect, the front edge <NUM> and the rear edge <NUM> are formed as curved surfaces continuous from the positive-pressure surface <NUM> and the negative-pressure surface <NUM>. As described above, the path R should be along the post-cutting surface; more specifically, the path R is determined by interpolating the closed curve C after the closed curve C has been prepared on a post-machining ideal shape (model). It is to be noted that the direction in which the cutting edge <NUM> extends may be inclined relative to the surface normal of the cutting point, so that a lead angle is formed.

As illustrated in <FIG>, the closed curve C is made to pass through imaginary lattice points P, which are set on the ridges of the front edge <NUM> and the rear edge <NUM>. The lattice points P on the ridge of the front edge <NUM> and the lattice points P on the ridge of the rear edge <NUM> are the same in number and are set by dividing each ridge into a predetermined number of ridge pieces. A closed curve C is set such that the closed curve C passes through: a front-edge lattice point P that is among the lattice points P set on the front edge <NUM> and that has an arrangement order as counted from the rotor disc <NUM>; and a rear-edge lattice point P that is among the lattice points P set on the rear edge <NUM> and that has the same arrangement order as counted from the rotor disc <NUM>. Further, the path R may be determined by interpolating the curve C such that, for example, the curve C passes through one of the two lattice points P that is set on one of the ridges. First, a vector from a first lattice point to the next lattice point is obtained. Then, points are set on the closed curve C; the distance on the closed curve C between the lattice point and each of the points is obtained; and a ratio of the distance to the length of the closed curve C is obtained. Then, at each point, the above-described vector is multiplied by the ratio obtained at the each point, resulting in another vector. The another vector is added to the above-described vector, thereby obtaining a new point. An interpolation is performed at this new point, thereby obtaining the path R. It is to be noted that each of the lattice points P may be selected from, for example, division points obtained by dividing the ridge at equal intervals. Selecting a lattice point P from equal-interval division points makes the setting of the lattice point P less laborious. Also, setting the lattice points P at equal intervals uniformizes the amount of cutting per circumferential movement. This stabilizes the cutting as a whole, contributing to highly accurate machining. Also, the closed curve C is preferably set along the flow of air (see arrow W) occurring on the blade <NUM> in an application in which the integrally bladed rotor <NUM> is incorporated in a turbine and turned into motion. It is to be noted that while a single arrow W is illustrated in the figure, the closed curve C is set based on varying flows of air on different parts of the blade <NUM>. This ensures that a resulting cutting trace is formed along the direction in which air flows, making the blade <NUM> superior in aerodynamic characteristics.

Referring to <FIG>, a possible example of machining equipment used to cut the integrally bladed rotor <NUM> is as follows. This machining equipment includes: a table <NUM>, which fixes the center axis, A2, of the rotor disc <NUM> of the integrally bladed rotor <NUM> in the vertical direction; and a tool holder <NUM>, which holds the turning tool <NUM> and is rotational about a rotation axis A1. By holding the turning tool <NUM>, the tool holder <NUM> makes the cutting edge <NUM> of the turning tool <NUM> rotational about the rotation axis A1. The rotation axis A1 of the tool holder <NUM> is set in a horizontal direction, for example, and extends toward the inside of the rotor disc <NUM>. In this respect, the table <NUM> and the tool holder <NUM> are movable relative to each other in a surface perpendicular to the rotation axis A1 in three linear axis directions, namely, the horizontal X axis direction, the vertical Y axis direction, and the Z axis direction, which is parallel to the rotation axis A1. Also, the table <NUM> is rotational about the center axis A2. That is, the above-described cutting is made possible by a combination of three linear axes and two rotational axes.

As described above, it is preferable that during the cutting, the direction of extension of the cutting edge <NUM> of the chip <NUM>, which is fixed to the leading end portion of the turning tool <NUM>, is parallel to a surface normal of the cutting point of the blade <NUM>. The orientation of the cutting edge <NUM> is approximately perpendicular to the rotation axis A1 (see <FIG>). For example, when it is necessary to make the orientation of the cutting edge <NUM> inclined in the X-Y plane, it is possible to rotate the tool holder <NUM> about the rotation axis A1. When it is necessary to make the orientation of the cutting edge <NUM> inclined in the X-Z plane, it is possible to combine a linear movement in the X axis direction and a rotation about the center axis A2 of the rotor disc <NUM>. By combining the inclination in the X-Y plane and the inclination in the X-Z plane, the orientation of the cutting edge <NUM> can be made parallel to a surface normal of the cutting point. By combining the resulting combination with the above-described three-axis linear movements, the blade <NUM> can be cut while the cutting edge <NUM> is being circumferentially moved along the closed curve C and following the path R. That is, the integrally bladed rotor <NUM> is obtained by being cut such that the blade <NUM> is positioned in the closed curve C.

As far as an integrally bladed rotor is concerned, the blade <NUM> may in some cases be cut into such a shape that it is not necessary to make the orientation of the cutting edge <NUM> inclined in the X-Z plane. In this case, the above-described cutting is made possible by a combination of three linear axes and one rotational axis (rotation about the rotation axis A1 of the tool holder <NUM>), without the need for the rotation of the table <NUM> about the center axis A2.

It is also possible to use such machining equipment that is capable of a combination of three linear axes and three rotational axes, which has an additional one rotational axis as compared with the above-described combination of three linear axes and two rotational axes. For example, it is possible to rotate the table <NUM> about a center axis parallel to the X axis. This increases the degree of freedom of cutting.

Incidentally, conventional practice was to use a rotating tool such as an end mill <NUM> illustrated in <FIG> to perform finishing of a blade of an integrally bladed rotor. If such rotating tool is used, its cutting edge contacts the to-be-cut object intermittently, and thus the cutting resistance changes intermittently as illustrated in <FIG>. This makes chatter more likely to occur during machining. Also, the intermittent contacts might leave wavy cutting traces on the cutting surface of the to-be-cut object, as illustrated in <FIG>, which shows a cross-section of the to-be-cut object.

In contrast, the embodiment of the present invention is such that the closed curve C continues in a spiral shape when circumferentially moving around the blade <NUM>. As a result of this interpolation, the path R is obtained for the cutting point to be moved on while the blade <NUM> is being cut. This configuration ensures that a uniform cutting load is obtained, making chatter less likely to occur. The above configuration also ensures that a smooth cutting surface is obtained, resulting in highly accurate machining of the blade <NUM>. Also, even if the above-described cutting trace is left, it is possible to make the cutting trace oriented along the direction in which air flows. This makes the blade <NUM> superior in aerodynamic characteristics.

Next, a program for cutting the above-described blade <NUM> of the integrally bladed rotor <NUM> will be described by referring to <FIG>.

Referring to <FIG>, first, a three-dimensional model of the blade <NUM> of the integrally bladed rotor <NUM> to be produced is obtained (S1). A mesh of a three-dimensional coordinate system is placed over this three-dimensional model so that the intersection between the mesh and the surface of the blade <NUM> is indicated by coordinate points (see <FIG>). The coordinate points are input into a predetermined computer such as a PC, or may be input directly into the machining equipment to be used.

Then, a closed curve C, which surrounds the blade <NUM>, is set on this three-dimensional model (S2). Specifically, first, a number of lattice points P are set on the ridge of the front edge <NUM>, and the same number of lattice points P are set on the ridge of the rear edge <NUM>. The number of the lattice points P, the positions of the lattice points P, and other parameters associated with the lattice points P are input by a worker. Then, the closed curve C is connected to the lattice points such that the closed curve C passes through: the same arrangement-order lattice points P on the ridges counted from the rotor disc <NUM>; the positive-pressure surface <NUM>; and the negative-pressure surface <NUM> (see <FIG>).

Next, tool dimensions are defined (S3). Tool dimensions include: the orientation of the cutting edge <NUM> and the position of the leading end portion of the cutting edge <NUM> in the turning tool <NUM>; and the orientation and the position of the cutting edge <NUM> relative to the tool holder <NUM> and its rotation axis A1 with the turning tool <NUM> held by the tool holder <NUM>. These tool dimensions are input by the worker.

Next, a tool path is defined (S4). In this example, the path R is determined as the tool path. The path R is made by making a feed movement from the leading end portion toward the base end portion of the blade <NUM> while making a circumferential movement around the blade <NUM> along the closed curve C. That is, the path R is made by making such an interpolation that the closed curve C continues in a spiral shape. Also, a surface normal of each cutting point on the path R is calculated and determined on the three-dimensional model.

Next, axial directions of the tool are defined (S5). In this example, the axial directions are determined by the worker from the axes described earlier, namely: three linear axes and one rotational axis; three linear axes and two rotational axes; and three linear axes and three rotational axes. For example, when it is not necessary to rotate the tool about the center axis A2 of the rotor disc <NUM>, three linear axes and one rotational axis are determined as the movement axes of the machining equipment, and input by the worker.

Next, an orientation of the cutting edge <NUM> of the turning tool <NUM> at each cutting point on the above-described tool path (the path R) is defined (S6). Specifically, the angle of rotation about the rotation axis A1 of the tool holder <NUM>, which holds the turning tool <NUM>, and related parameters are determined such that the orientation of the cutting edge <NUM> is parallel to the surface normal determined at S4. It is possible to form a lead angle, as described earlier.

With these settings done, machining command data is generated along the tool path (S7). Specifically, at each cutting point, a combination of tool vectors indicating the position of the cutting edge <NUM> and the direction of the turning tool (for example, the orientation of the cutting edge <NUM>) and a vector of the surface normal is prepared. Then, based on the combination, the movement direction of the turning tool <NUM> is determined.

Next, tool information and machining positions are input into the machining equipment (S8). In this example, a to-be-machined integrally bladed rotor <NUM>, which is done with rough machining, is fixed. With the integrally bladed rotor <NUM> fixed, the turning tool <NUM> is held on the machining equipment. The worker inputs the initial position of the turning tool <NUM> into the machining equipment. The above-described machining command data generated in the computer is also input into the machining equipment.

Next, the machining equipment is caused to perform cutting based on the machining command data. Specifically, the machining equipment performs finishing of the blade <NUM> by cutting the blade <NUM> along the above-described path R.

Next, a dimension examination of the post-machined blade <NUM> is performed. Specifically, the blade <NUM> is checked on the machining equipment as to whether the blade <NUM> meets machining-finished dimensions (S10). More specifically, the blade <NUM> is checked as to whether the dimensions of the blade <NUM> are within predetermined margins of error as compared with the dimensions of the above-described three-dimensional model. The results are held as cutting information.

In this respect, when the blade <NUM> does not meet machining-finished dimensions (S10: No), the tool information is modified based on the machining-finished dimensions and the margins (necessary amounts of machining). The worker re-inputs the tool information (S8), and similar cutting is further performed (S9). That is, the machining command data is changed as well based on the tool information modified based on the above-described cutting information. When the blade <NUM> meets the machining-finished dimensions (S10: Yes), the finishing is ended.

Thus, the machining equipment is caused to perform cutting along the path R, which is formed by such an interpolation that the above-described closed curve C continues in a spiral shape. This ensures that a blade <NUM> superior in aerodynamic characteristics is machined highly accurately.

Claim 1:
A method for producing an integrally bladed rotor (<NUM>), the integrally bladed rotor (<NUM>) comprising a rotor disc (<NUM>) and a three-dimensional and planar blade (<NUM>) that is integral to the rotor disc (<NUM>) and that has a positive-pressure surface (<NUM>) and a negative-pressure surface (<NUM>) as main surfaces, the method comprising:
rough machining the integrally bladed rotor (<NUM>) and the blade (<NUM>) of the integrally bladed rotor (<NUM>) into a wing shape;
obtaining a three-dimensional model of the blade (<NUM>) of the integrally bladed rotor (<NUM>) to be produced;
on the three-dimensional model:
dividing a ridge of a front edge (<NUM>) of the blade (<NUM>) and a ridge of a rear edge (<NUM>) of the blade (<NUM>) into a predetermined number of ridge pieces,
setting imaginary lattice points (P) on the respective ridge pieces, and
setting a closed curve (C) around the blade (<NUM>) such that the closed curve (C) passes through: a front-edge imaginary lattice point (P) that is among the imaginary lattice points (P) set on the front edge (<NUM>) and that has an arrangement order as counted from the rotor disc (<NUM>); a rear-edge imaginary lattice point (P) that is among the imaginary lattice points (P) set on the rear edge (<NUM>) and that has the same arrangement order as counted from the rotor disc (<NUM>); the positive-pressure surface (<NUM>); and the negative-pressure surface (<NUM>);
the method further comprising:
preparing a machining command for forming the closed curve (C) continuously in a spiral shape and causing a cutting edge (<NUM>) of a turning tool (<NUM>) to interpolate the closed curve (C) by moving along the spiral shape; and
based on the machining command, cutting the blade (<NUM>) by circumferentially moving a cutting point around the blade (<NUM>), the cutting point corresponding to a position of the cutting edge (<NUM>).