整体叶盘精密电解加工工艺

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 to

Blisk Manufacturing

EMAG ECM GmbH, 2012

Abstract

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 2020

European 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 action

35% reduction in production costs

20% reduction in development time

20% reduction in fuel consumption

Increased reliability

10 dB reduction in sound level

20% reduction in CO2 emissions

80% reduction in NOx

Optimization of airspace use

25% reduction in maintenance costs

Reduced 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