埃马克电化学公司关于整体叶盘精密电解加工工艺综述面向未来的技术EMAG ECM GmbH- A PECM Cost-Saving Approach toBlisk ManufacturingEMAG ECM GmbH, 2012Abstract摘要整体叶盘的出现是为了满足市场的需求，与传统转子叶片和轮盘分离的装配式叶盘相比，由于减少了传统连接中的榫头，榫槽等装配零件，叶轮边缘负载降低，重量减轻高达30%，同时由于避免了榫头气流损失也即减少动力消耗，从而也提高气动效率并显著提高功率，有助于减少燃油消耗和废气排放。
追溯其发展历史最初应用到高压压气机以及商用压气机末端上。
是现代燃气涡轮发动机中最具创新和挑战的零部件。
The emergence of BLISK(Bladed integrated Disk) is in order to meet the market demand calls, comparing with conventional separable assembled rotor blades and disk counterparts, due to the reduction in the conventional connector assembly parts of the disk lugs, blade root groove, etc.; the rim load lower. The essential advantages are that they reduce weight up to 30% as well as reduce aerodynamic losses by avoiding disk lugs air leakage flows, thus improve aerodynamic efficiency and the power output, specially it enables reduce in fuel consumption and exhaust gas volume emissions. Retracing the history of Blisk development, it’s application initially used in high-pressure compressors and commercial compressors. It is the most innovative and challenging components of modern gas turbine engine.图1: 整体叶盘模拟图 Fig. 1: CAD Blisk市场需求情况-应对2020年需求的挑战Markt demond-Preparing for the Global Challenges of 2020European aviation is experiencing a golden age which shows no sign of slowing. The continuous growth in world air transport - passengers and freight - experienced since the 1960s is set to continue at a rate of at least 5% a year over the next two decades. The latest Airbus forecasts indicate that this will mean a demand for 7600 new aircraft every decade - or a market estimated at 1300 billion Euros by 2019. As a vital sector in the European - and American - industrial dynamic, aircraft manufacture must therefore continue to innovate if it is to win these large markets.自从1960年以来航空业一直维持每年近5%的持续的年增长率，欧洲航空空客业乐观的预测下一个12年直到2019年的平均年增长率会保持不变，这也就意味着在2020年前将会有7200架新的飞机需求（客运以及货运）/也即13000亿欧元的市场份额。
想要赢得这个巨大的市场份额，无论欧洲还是美国都必须全面投入新的技术革新来争取。
The main objectives of the Aeronautics key action35% reduction in production costs20% reduction in development time20% reduction in fuel consumptionIncreased reliability10 dB reduction in sound level20% reduction in CO2 emissions80% reduction in NOxOptimization of airspace use25% reduction in maintenance costsReduced rate of accidents数据来源Quelle: http://ec.europa.eu/research/rtdinfo/en/28/aero1.html航空业需要达到的重点行动目标生产成本降低35％开发时间减少20％燃料消耗减少20％提高可靠性噪音水平减少10分贝减少20％的二氧化碳排放量减少80％的氮氧化物优化空域使用维护费用降低25％降低事故发生率图2:世界人口每人公里数飞行预测Fig.: Flight amount in personal-kilometer worldwide份额年Growth in the production and use of blisks becomes clearly apparent. The trend is driven also by increasing use in commercial engines. In the face of aggravating competition, individual AND cost saving manufacturing processes and moreover complete tailor made short foot prints- process chains need continuous optimization to satisfy market requirements. 整体叶盘的生产及应用是显而易见的。
这种趋势的主要缘由是来自民用需求。
面对激烈的市场竞争，独立并且经济的工艺是首选，特别是量身订制的缩短工艺路线路径的全套方案更需要优化以满足市场的需求整体叶盘主要制造技术Main approaches for manufacturing blisk airfoils整体叶盘目前主要加工工艺The major alternative process for blisk machining:•高效整体铣削High Performance overall milling•多轴联动数控精密电解: 由于整体刀具成本的显著降低，电解以及精密电解正在发展成为高温合金材料整体叶盘最佳的加工工艺Multi-axis linkage CNC PECM (precise electrochemical machining): Due to the significant tool cost saving, precise electro-chemical machining (PECM) is developing to become the most preferred manufacturing approach for blisk in nickel alloys.埃马克电化学有限公司最新开发的PO 900 BF精密多轴联动高频窄脉冲电解加工中心及全套交钥匙工艺-从整体叶盘毛坯的初成行叶片套料加工(大量去除材料初步选择性的实现叶片扭曲角度以及叶片轮廓)直到最终叶片型面成型完整的工艺链工件交钥匙解决方案。
EMAG ECM GmbH developed its own new multi-axis PECM machining center and a whole tailor made process turnkey solution- from blisk rough majority material removing (masking roughing machining for majority material removing results in airfoil twisting pre-conture) till airfoil profile final conture.1. 高效整体铣削High Performance overall millingThis refers to cutting processes used to manufacture airfoils on 5- or 6-axis machine tools , with differentiation being made between rough and finish cutting. Typical processes of the kind are circular stagger milling in conjunction with high-performance tools and high-pressure internal cooling for the rough cut, The most common practice is point milling using a ball-end cutter and stripe or flank milling, etc., for the finish cut.高效整体铣削技术是指在5或6轴加工中心加工上来进行叶片的粗加工和精加工。
典型工艺是循环交错铣结合高效能的设备和高压力内部冷却进行粗切削，叶盘精加工最常见的做法是用球面铣刀点球铣，侧铣与条纹铣等。