CN111545990B - Method for taking out broken interference stud in casing - Google Patents
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- CN111545990B CN111545990B CN201910110040.4A CN201910110040A CN111545990B CN 111545990 B CN111545990 B CN 111545990B CN 201910110040 A CN201910110040 A CN 201910110040A CN 111545990 B CN111545990 B CN 111545990B
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Abstract
The invention provides a method for taking out a broken interference stud in a casing, which comprises the following steps: s1Selecting a cobalt-containing high-speed steel drill bit to drill and machine a broken interference stud in the casing; s2Calculating the diameter of the required drill bit according to the small diameter size of the interference thread on the interference stud and the analyzed main error of the process system; s3Milling the upper surface of the broken stud by using a hard alloy milling cutter; s4Drilling a point by using a center drill; s5Drilling by adopting a high-speed steel drill bit; s6And cleaning the residual interference stud in the threaded hole of the casing. The invention solves the problem that a cutter for drilling or milling the fractured high-temperature alloy interference stud in the casing is easy to break, and realizes the high-efficiency and low-cost extraction of various fractured high-temperature alloy interference studs in the casing. The reliability is high, and the popularization value is high.
Description
Technical Field
The invention relates to the field of aeroengines, in particular to a method for taking out a broken interference stud in a casing.
Background
In the field of aircraft engines, the aircraft engines are complex in structure and multiple in parts, and the common connection mode of common studs and nuts cannot be used due to reasons such as insufficient wrench space, non-conformity in connection reliability and the like. The interference stud is used as a common fastener of the aero-engine and is widely applied to connection of front and rear bearing machine case components, interstage case components, intermediate case components and the like. The interference stud material for aviation is a high-strength material which is difficult to process, such as high-temperature alloy.
The interference threaded connection of the aero-engine has strict requirements on the installation torque, and for example, CG interference threads are taken as the example, the CG6 interference threaded installation torque is generally (8-15) N.m, and the CG8 interference threaded installation torque is generally (17.8-33.8) N.m. During installation, the studs risk breaking if the installation method is not correct.
Meanwhile, the engine is often required to replace the interference stud after test. Due to the influence of high temperature, high pressure and large load, the situation that the screw thread is blocked and cannot be normally disassembled can occur in the replacement process. The interference stud breaks directly during disassembly, especially when cyclic loads in the test run cause it to fatigue crack at stress concentrations.
Broken and stuck interference studs cannot be taken out by adopting a simple and common method for taking out broken studs, such as removing by clamping, screwing out welded nuts and the like. Generally, the broken interference studs can be removed by spark or machining.
However, the electric spark machining has the problem of low machining efficiency, meanwhile, electrolyte needs to be poured in the machining process, titanium alloy parts and a coating on a casing, which are widely adopted by an aircraft engine, are easy to pollute, and the application of the electric spark machining is further limited. The mechanical processing mode has higher requirements on the whole process system, and relates to a clamping and aligning method, cutting tool selection, processing parameter adjustment, equipment selection and the like.
The broken interference stud is different from a common non-interference stud, the pitch diameter of the interference stud is in interference fit with the pitch diameter of a threaded hole in the casing, and the disassembly difficulty is extremely high. The reason is as follows:
firstly, the torque required by unscrewing is large and can reach more than 33.8 N.m, and the screw cannot be unscrewed after being broken;
GH4169 is a high-strength material, so that the mechanical processing performance is poor, and the processing efficiency is low;
third, the thread of the threaded hole on the inner casing cannot be damaged in the machining process;
fourthly, along with the damage of the interference stud, the length of the interference fit is continuously reduced, the moment is continuously changed, and reasonable technological parameters are selected to control the vibration caused by the cutting force;
and fifthly, the requirement of the casing on mechanical properties is high, and a special coating possibly exists, so that a welding or electric machining method is not suitable to be used generally.
In view of the above, those skilled in the art are in great need to develop a new method for removing a broken interference stud in a casing, so as to solve the above problems.
Disclosure of Invention
The invention aims to overcome the defect that a common method in the prior art cannot safely take out a broken interference stud, and provides a method for taking out a broken interference stud in a casing.
The invention solves the technical problems through the following technical scheme:
a method for taking out a broken interference stud in a casing is characterized by comprising the following steps:
S1selecting a cobalt-containing high-speed steel drill bit to drill and machine a broken interference stud in the casing;
S2calculating the diameter of the required drill bit according to the small diameter size of the interference thread on the interference stud and the analyzed main error of the process system;
S3milling the upper surface of the broken stud by using a hard alloy milling cutter;
S4drilling a point by using a center drill;
S5drilling by adopting a high-speed steel drill bit;
S6and cleaning the residual interference stud in the threaded hole of the casing.
According to an embodiment of the invention, said step S2The calculation formula adopted is as follows: the diameter of the drill bit is equal to the small diameter of the interference stud, the alignment error, the error of the rotary tool holder and the theoretical allowance size.
According to one embodiment of the invention, the method for calculating the alignment error comprises the following steps:
S21after the cartridge receiver reference is aligned on the machine tool, the position of the broken interference stud is defined as an angular zero point, and the theoretical positions of the rest interference studs are calculated;
S22randomly selecting n interference studs (n +1 is less than or equal to the total number of the interference studs) on the casing, measuring the actual positions of the interference studs on the machine tool, wherein the distance between the measured positions and a theoretical value is Xk, and the alignment error is equal to
Considering the processing efficiency, k can be 2-3.
According to an embodiment of the invention, the theoretical allowance size is (0.05-0.15) mm.
According to one embodiment of the invention, the error of the rotary knife handle is obtained by measuring on equipment by using a dial indicator, and the knife handle is replaced when the error of the rotary knife handle is more than or equal to 0.05 mm.
According to an embodiment of the invention, said step S21Further comprising the steps of:
S211aligning the radial process reference and the end face process reference of the casing by using a dial indicator, selecting at least 4 points by adopting point alignment, wherein the difference value of the point alignment is not more than 0.005 mm;
S212and finding out the position coordinates of the central line of the broken interference stud by using a dial indicator on the machine tool, and recording.
According to an embodiment of the invention, said step S22Further comprising the steps of:
S221randomly selecting 3 unbroken interference screw piles, finding out the position coordinates of the center line of the interference screw pile by using a dial indicator, and recording;
S222and calculating the theoretical position of each interference stud according to the theoretical position relationship of each interference stud in the design drawing, comparing the theoretical position with the actual position measured on the machine tool, calculating the distance to obtain X1, X2 and X3, and obtaining the alignment error (X1+ X2+ X3)/3.
According to an embodiment of the invention, said step S3The diameter of the medium hard alloy milling cutter is 8mm, the rotating speed (350-400) r/min and the feeding amount is 20 mm/min.
According to an embodiment of the invention, said step S4The diameter of the center drill is 3mm, the dotting depth is 3mm, the rotating speed is 750-850 r/min, and the feeding amount is 10 mm/min.
According to an embodiment of the invention, said step S5The rotation speed (80-100) r/min and the feed rate (10 mm/min) of the medium-speed steel drill bit are achieved, a pecking drilling processing mode is adopted, the processing amount is (0.15-0.2) mm each time, the cutter withdrawal speed is (150-180) mm/min, and the cutter withdrawal speed is 2mm higher than the upper surface of the stud each time.
The positive progress effects of the invention are as follows:
the method for taking out the broken interference stud in the casing solves the problem that a cutter for drilling or milling the broken high-temperature alloy interference stud in the casing is easy to break, and realizes the high-efficiency and low-cost taking out of various types of broken high-temperature alloy interference studs in the casing. The reliability is high, and the popularization value is high. The used process equipment has wide resources, does not need to use special process equipment and has lower cost. Compared with an electric spark method, the required processing time can be reduced by more than 50%, and the time cost of reworking and repairing the aeroengine is effectively reduced.
Drawings
The above and other features, properties and advantages of the present invention will become more apparent from the following description of the embodiments with reference to the accompanying drawings in which like reference numerals denote like features throughout the several views, wherein:
fig. 1 is a schematic view of a radial alignment datum in the method for removing a broken interference stud in a casing according to the present invention.
Fig. 2 is a schematic diagram of an angular alignment position and an end face alignment reference in the method for taking out a broken interference stud in a casing.
[ reference numerals ]
Detailed Description
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below.
Embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
Further, although the terms used in the present invention are selected from publicly known and used terms, some of the terms mentioned in the description of the present invention may be selected by the applicant at his or her discretion, the detailed meanings of which are described in relevant parts of the description herein.
Furthermore, it is required that the present invention is understood, not simply by the actual terms used but by the meaning of each term lying within.
Fig. 1 is a schematic view of a radial alignment datum in the method for removing a broken interference stud in a casing according to the present invention. Fig. 2 is a schematic diagram of an angular alignment position and an end face alignment reference in the method for taking out a broken interference stud in a casing.
As shown in fig. 1 and 2, the invention discloses a method for taking out a broken interference stud in a casing, which comprises the following steps:
step S1And selecting a cobalt-containing high-speed steel drill bit to drill and machine the broken interference stud 20 in the casing. For example, with GH4169 interference studs, the drill bit top angle is re-sharpened, preferably at a top angle of 100 °.
For example, if the drilling depth is H (mm) and the diameter of the drill is d (mm), the length of the drill edge after sharpening is L (H +1/2tan40 ° d +10) mm.
Step S2And calculating the diameter of the required drill bit according to the small diameter size of the interference thread on the interference stud 20 and the analyzed main error of the process system.
Wherein, the step S2The calculation formula adopted is as follows: the diameter of the drill bit is equal to the small diameter of the interference stud, the alignment error, the error of the rotary tool holder and the theoretical allowance size. Wherein the small diameter dimension of the interference stud can be known by looking up the standard of the interference stud.
In particular, the theoretical residual size is generally (0.05-0.15) mm, and can be generally obtained from empirical data. This is also comparatively critical, and too big clearance interference stud is difficult, seriously influences and takes out efficiency. Too small can damage the internal threads of the case.
The error of the rotary knife handle is measured on equipment by a dial indicator, and the knife handle is replaced when the error of the rotary knife handle is larger than or equal to 0.05 mm. The cutting parameters are that the rotating speed S is preferably (80-120) r/min, the feed F is preferably (8-10) mm/min, the processing depth a of the pecking drill per time is preferably (0.15-0.2) mm, and the cutting parameters return to the reference plane after each drilling.
Preferably, the method for calculating the alignment error includes:
step S21After the datum of the casing 10 is aligned on the machine tool, the position of the broken interference stud 20 is defined as an angular zero point, and theoretical positions of other interference studs are calculatedPlacing;
step S22Randomly selecting n interference studs (n +1 is less than or equal to the total number of the interference studs) on the casing 10, measuring the actual positions of the interference studs on a machine tool, wherein the distance between the measured positions and a theoretical value is Xk, and the alignment error is equal to
In view of processing efficiency, k may be 2 to 3 in general.
Further, the step S21Further comprising the steps of:
step S211Aligning the radial process datum and the end face process datum of the casing 10 by using a dial indicator, selecting at least 4 points by adopting point alignment, wherein the difference value of the point alignment is not more than 0.005 mm;
step S212And finding out the position coordinates of the central line of the broken interference stud 20 by using a dial indicator on the machine tool, and recording.
Further, the step S22Further comprising the steps of:
step S221Randomly selecting 3 unbroken interference screw piles, finding out the position coordinates of the center line of the interference screw pile by using a dial indicator, and recording;
step S222And calculating the theoretical position of each interference stud according to the theoretical position relationship of each interference stud in the design drawing, comparing the theoretical position with the actual position measured on the machine tool, calculating the distance to obtain X1, X2 and X3, and obtaining the alignment error (X1+ X2+ X3)/3.
Step S3And milling the upper surface of the broken stud by using a hard alloy milling cutter. Preferably, the diameter of the hard alloy milling cutter is 8mm, the rotating speed (350-400) r/min and the feeding amount is 20 mm/min.
Step S4And dotting by using a central drill. Preferably, the diameter of the center drill is 3mm, the dotting depth is 3mm, the rotating speed (750-850) r/min and the feeding amount is 10 mm/min.
Step S5And drilling by using a high-speed steel drill bit. The high-speed steel drill bit has the rotating speed of 80-100 r/min and the feeding amount of 10mm/min, and adopts a pecking drill processing mode, wherein the processing amount is 0.15-0.2 mm every time, and every timeThe tool withdrawal speed is 150-180 mm/min, which is 2mm higher than the upper surface of the stud. Wherein the diameter of the high-speed steel drill bit is obtained through calculation.
Step S6And cleaning the residual interference stud in the threaded hole of the casing 10.
In light of the foregoing description, two more specific examples are provided below for further illustration, but the following two examples are only illustrative and do not limit the scope of the present invention.
The first embodiment is as follows:
the method is characterized in that an interference stud of CG8 multiplied by 1.25 high-temperature alloy (GH4169) is drilled, the length of the broken stud in the inner part of a casing is about 10mm, the length of the broken stud in the outer part of the casing is about 6mm, and the machining steps are as follows:
the method comprises the following steps: aligning the radial process datum and the end face process datum of the casing by using a dial indicator, allowing the alignment of point alignment to be not less than 4 points, and enabling the difference value of the point alignment to be not more than 0.005 mm;
step two: finding out the position coordinates of the central line of the broken interference stud by using a dial indicator on a machine tool, and recording;
step three: randomly selecting 3 unbroken interference screw piles, finding out the position coordinates of the center line of the interference screw pile by using a dial indicator, and recording;
step four: calculating the theoretical position of the selected interference stud according to the theoretical position relation of each interference stud in a design drawing, comparing the theoretical position with the actual position measured on a machine tool, and calculating the distance to obtain X1, X2 and X3, wherein the obtained alignment error is (X1+ X2+ X3)/3, and the calculated value in the case is 0.08 mm;
step five: measuring a jumping value of the cutter rotating around the main shaft on a machine tool by using a dial indicator, recording the jumping value as a rotary cutter error, wherein the jumping value is less than 0.05mm, and the actual measurement is 0.02 mm;
step six: according to the formula: the diameter of the drill bit is 6.64-0.08-0.02, and the diameter of the drill bit is 6.54-theoretical allowance size. The theoretical allowance size is 0.14mm and the diameter of the drill bit is 6.4mm in consideration of roundness.
Step seven: using a phi 8 hard alloy milling cutter to mill the upper surface of the broken stud flat, wherein the rotating speed is 350-400 r/min, and the feeding amount is 20 mm/min;
step eight: drilling a point by using a phi 3 center, wherein the drilling depth is 3mm, the rotating speed (750-850) r/min and the feeding amount is 10 mm/min;
step nine: drilling with a phi 6.4mm high-speed steel drill bit at the rotating speed of 80-100 r/min and the feeding amount of 10mm/min, adopting a pecking drilling processing mode, wherein the processing amount is (0.15-0.2) mm each time, the tool withdrawal speed is (150-180) mm/min, and the upper surface of the stud is 2mm higher than the upper surface of the stud each time.
Step ten: and cleaning the residual interference stud in the threaded hole of the casing.
Example two:
the method adopts an interference stud drilled with CG6 multiplied by 1.25 high-temperature alloy (GH4169), the length of the broken stud in a casing is about 6mm, the length of the broken stud in the casing is about 3mm, and the processing steps are as follows:
the method comprises the following steps: aligning the radial process datum and the end face process datum of the casing by using a dial indicator, allowing the alignment of point alignment to be not less than 4 points, and enabling the difference value of the point alignment to be not more than 0.005 mm;
step two: finding out the position coordinates of the central line of the broken interference stud by using a dial indicator on a machine tool, and recording;
step three: randomly selecting 3 unbroken interference screw piles, finding out the position coordinates of the center line of the interference screw pile by using a dial indicator, and recording;
step four: calculating the theoretical position of the selected interference stud according to the theoretical position relation of each interference stud in a design drawing, comparing the theoretical position with the actual position measured on a machine tool, and calculating the distance to obtain X1, X2 and X3, wherein the alignment error position is equal to (X1+ X2+ X3)/3, and the calculated value in the case is 0.07 mm;
step five: measuring a jumping value of the cutter rotating around the main shaft on a machine tool by using a dial indicator, recording the jumping value as a rotary cutter error, wherein the jumping value is less than 0.05mm, and the actual measurement is 0.02 mm;
step six: according to the formula: the diameter of the drill bit is 4.917-0.07-0.02, and the diameter of the drill bit is 4.827-theoretical allowance size. The theoretical allowance size is 0.127mm in consideration of roundness, and the diameter of the drill bit is 4.7 mm.
Step seven: using a phi 8 hard alloy milling cutter to mill the upper surface of the broken stud flat, wherein the rotating speed is 350-400 r/min, and the feeding amount is 20 mm/min;
step eight: using phi 3 center to perform dotting, wherein the dotting depth is 3mm, the rotating speed (750-850) r/min and the feeding amount is 10 mm/min;
step nine: drilling with a phi 4.7mm high-speed steel drill bit at the rotating speed (80-120) r/min and the feeding amount of 8mm/min, adopting a pecking drilling processing mode, wherein the processing amount is (0.10-0.15) mm each time, the tool withdrawal speed is (150-180) mm/min, and the upper surface of the stud is 2mm higher than the upper surface of the stud each time.
Step ten: and cleaning the residual interference stud in the threaded hole of the casing.
According to the description, the method for taking out the broken interference stud in the case has good stability and high reliability, and solves the problem that the broken GH4169 interference stud in the case of the aero-engine is difficult to take out. The clamping moment of the broken interference stud is static friction force generated by mutual extrusion of interference threads, and the static friction force between the interference threads is reduced due to continuous release of extrusion in the drilling process, so that the clamping moment is reduced.
Therefore, vibration and even relative displacement are easy to occur in the drilling process, and the cutting force caused by the relative displacement is changed rapidly, so that the cutter is easy to break instantly, and the phenomenon is further aggravated when a rough and fine combined machining mode widely adopted by materials difficult to machine is adopted. The technical scheme adopts a process method of drilling and finishing at one time, and vibration impact possibly received by the cutter is reduced to the greatest extent.
In addition, the method for taking out the broken interference stud in the casing also utilizes the characteristics of high toughness of the high-temperature alloy material difficult to machine and high hardness of the machined deterioration layer, and selects and calculates proper micro machining allowance to ensure that internal threads on the casing are not damaged. The running state of a part process system is analyzed, a high-speed steel cutting tool with weak processing capacity is selected, process parameters are reasonably optimized, the processing effect exceeding that of a hard alloy cutting tool is achieved in the process system, the processing cost is reduced, and meanwhile, the process quality is improved. Through process system analysis and example verification, a calculation method suitable for the process system is provided.
In conclusion, the method for taking out the broken interference stud in the casing solves the problem that a cutter for drilling or milling the broken high-temperature alloy interference stud in the casing is easy to break, and realizes the high-efficiency and low-cost taking out of the broken high-temperature alloy interference stud in the casing. The device has high reliability, and can be widely used for taking out broken interference screw piles with various diameters used for aeroengines. The used process equipment has wide resources, does not need to use special process equipment and has lower cost. Compared with an electric spark method, the required processing time can be reduced by more than 50%, and the time cost of reworking and repairing the aeroengine is effectively reduced.
The method for taking out the broken interference stud in the casing achieves the purpose of taking out the interference bolt with low cost and high efficiency, and simultaneously cannot cause pollution to other parts on the casing of the aero-engine. The method is characterized in that materials, assembling structure characteristics, stress states and the like of the broken interference screw pile are analyzed, and proper technological equipment and technological parameters are selected to achieve a stable machining state.
While specific embodiments of the invention have been described above, it will be appreciated by those skilled in the art that these are by way of example only, and that the scope of the invention is defined by the appended claims. Various changes and modifications to these embodiments may be made by those skilled in the art without departing from the spirit and scope of the invention, and these changes and modifications are within the scope of the invention.
Claims (8)
1. A method for taking out a broken interference stud in a casing is characterized by comprising the following steps:
S1selecting a cobalt-containing high-speed steel drill bit to drill and machine a broken interference stud in the casing;
S2calculating the diameter of the required drill bit according to the small diameter size of the interference thread on the interference stud and the analyzed main error of the process system;
S3using hard alloy milling cutter to make broken screw pileSurface milling;
S4drilling a point by using a center drill;
S5drilling by adopting a high-speed steel drill bit;
S6cleaning residual interference studs in the threaded holes of the casing;
said step S2The calculation formula adopted is as follows: the diameter of the drill bit is equal to the small diameter of the interference stud, the alignment error, the error of the rotary tool holder and the theoretical allowance size;
the method for calculating the alignment error comprises the following steps:
S21after the cartridge receiver reference is aligned on the machine tool, the position of the broken interference stud is defined as an angular zero point, and the theoretical positions of the rest interference studs are calculated;
S22randomly selecting n interference studs (n +1 is less than or equal to the total number of the interference studs) on the casing, measuring the actual positions of the interference studs on the machine tool, wherein the distance between the measured positions and a theoretical value is Xk, and the alignment error is equal to
Considering the processing efficiency, k can be 2-3.
2. The method for taking out the broken interference stud in the casing according to claim 1, wherein the theoretical allowance size is (0.05-0.15) mm.
3. The method for taking out the broken interference stud in the casing according to claim 1, wherein the error of the rotary tool shank is measured by a dial indicator on equipment, and the tool shank is replaced when the error of the rotary tool shank is larger than or equal to 0.05 mm.
4. The method for removing a broken interference stud in a casing according to claim 1, wherein the step S21Further comprising the steps of:
S211aligning the radial process reference and the end face process reference of the casing by using a dial indicator, selecting at least 4 points by adopting point alignment, wherein the difference value of the point alignment is not more than0.005mm；
S212And finding out the position coordinates of the central line of the broken interference stud by using a dial indicator on the machine tool, and recording.
5. The method for removing a broken interference stud in a casing according to claim 1, wherein the step S22Further comprising the steps of:
S221randomly selecting 3 unbroken interference screw piles, finding out the position coordinates of the center line of the interference screw pile by using a dial indicator, and recording;
S222and calculating the theoretical position of each interference stud according to the theoretical position relationship of each interference stud in the design drawing, comparing the theoretical position with the actual position measured on the machine tool, calculating the distance to obtain X1, X2 and X3, and obtaining the alignment error (X1+ X2+ X3)/3.
6. The method for removing a broken interference stud in a casing according to claim 1, wherein the step S3The diameter of the medium hard alloy milling cutter is 8mm, the rotating speed (350-400) r/min and the feeding amount is 20 mm/min.
7. The method for removing a broken interference stud in a casing according to claim 1, wherein the step S4The diameter of the center drill is 3mm, the dotting depth is 3mm, the rotating speed is 750-850 r/min, and the feeding amount is 10 mm/min.
8. The method for removing a broken interference stud in a casing according to claim 1, wherein the step S5The rotation speed (80-100) r/min and the feed rate (10 mm/min) of the medium-speed steel drill bit are achieved, a pecking drilling processing mode is adopted, the processing amount is (0.15-0.2) mm each time, the cutter withdrawal speed is (150-180) mm/min, and the cutter withdrawal speed is 2mm higher than the upper surface of the stud each time.
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| DE102012105498A1 (en) * | 2012-06-25 | 2014-04-03 | Margitta Gnauck | Method for drilling shaft of broken screw that connects base part and attaching part, has producing hole in screw shaft by drill, which is guided and centered in continuous, elongate guide hole, or completely drilling screw shaft |
| CN104646917A (en) * | 2013-11-21 | 2015-05-27 | 中船桂江造船有限公司 | Method for dismounting decollation bolt |
| CN104384824A (en) * | 2014-10-16 | 2015-03-04 | 沈阳黎明航空发动机(集团)有限责任公司 | Processing methods of High temperature alloy GH4169 special-shaped hole and hole edge fillet |
| CN104551091A (en) * | 2014-12-15 | 2015-04-29 | 贵州黎阳航空动力有限公司 | Method for machining small deep hole of part by using peck type variable speed drilling |
| CN104552133A (en) * | 2014-12-19 | 2015-04-29 | 连云港中复连众复合材料集团有限公司 | Taking-out method for embedded positioning screw bolt at root part of wind power blade |
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