Electrical discharge machining method and electrical discharge machining device

Abstract

An electrical discharge machining method includes selectively immersing only a portion of a workpiece in an electrical discharge machining liquid such that a machining object portion included in the portion of the workpiece is opposed to an electrode immersed in the electrical discharge machining liquid and applying an electrical discharge machining to the machining object portion by applying a voltage between the electrode and the workpiece in a state where the portion of the workpiece is selectively immersed in the electrical discharge machining liquid.

Claims

1. An electrical discharge machining method, comprising: selectively immersing only a portion of a blade in an electrical discharge machining liquid such that a blade tip surface included in the portion of the blade is opposed to an electrode immersed in the electrical discharge machining liquid; applying an electrical discharge machining to the blade tip surface by applying a voltage between the electrode and the blade in a state where the portion of the blade is selectively immersed in the electrical discharge machining liquid; fitting a root portion of the blade into a blade groove of a blade holder and attaching the blade to a feed unit of an electrical discharge machine via the blade holder; and pressing the blade by a datum part provided on the blade holder such that a bearing surface of the root portion of the blade contacts a wall surface of the blade holder, wherein, in the selectively immersing only the portion of the blade in the electrical discharge machining liquid, the blade moves to the electrode by the feed unit.

2. The electrical discharge machining method according to claim 1, wherein the electrode is kept stationary while the blade moves to the electrode by the feed unit.

3. The electrical discharge machining method according to claim 1, wherein the blade moves to the electrode by the feed unit from above the electrode such that the blade tip surface is opposed to an upper surface of the electrode.

4. The electrical discharge machining method according to claim 1, wherein the blade is a blade for a downstream stage of a compressor of a gas turbine.

5. An electrical discharge machining method, comprising: selectively immersing only a portion of a blade in an electrical discharge machining liquid such that a blade tip surface included in the portion of the blade is opposed to an electrode immersed in the electrical discharge machining liquid; applying an electrical discharge machining to the blade tip surface by applying a voltage between the electrode and the blade in a state where the portion of the blade is selectively immersed in the electrical discharge machining liquid; fitting a root portion of the blade into a blade groove of a blade holder and attaching the blade to a feed unit of an electrical discharge machine via the blade holder; and bringing one end face of the root portion of the blade in an extending direction of the blade groove of the blade holder into contact with a datum block inserted into the blade groove of the blade holder, wherein, in the selectively immersing only the portion of the blade in the electrical discharge machining liquid, the blade moves to the electrode by the feed unit.

6. An electrical discharge machining device for a blade, the electrical discharge machining device comprising: a feed unit; a blade holder attached to the feed unit and having a blade groove into which a root portion of the blade is fittable; an electrode immersed in an electrical discharge machining liquid; and a power source for applying a voltage between the blade and the electrode, wherein the blade holder includes a pressing member for pressing the blade toward a wall surface of the blade holder such that a bearing surface of the root portion of the blade is brought into contact with the wall surface of the blade holder.

7. An electrical discharge machining device for a blade, the electrical discharge machining device comprising: a feed unit; a blade holder attached to the feed unit and having a blade groove into which a root portion of the blade is fittable; an electrode immersed in an electrical discharge machining liquid; a power source for applying a voltage between the blade and the electrode; and a datum block configured to be at least partially inserted into the blade groove of the blade holder such that one end face of the root portion of the blade in an extending direction of the blade groove of the blade holder is brought into contact with the datum block.

8. An electrical discharge machining device for a blade, the electrical discharge machining device comprising: a feed unit; a blade holder attached to the feed unit and having a blade groove into which a root portion of the blade is fittable; an electrode immersed in an electrical discharge machining liquid; and a power source for applying a voltage between the blade and the electrode, wherein: an upper surface of the electrode includes a curved concave surface shape; and a height of the upper surface of the electrode decreases from both ends of the electrode in a horizontal direction to a center of the electrode in the horizontal direction.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a schematic view showing a schematic configuration of an electrical discharge machining device 2 according to an embodiment of the present invention.

(2) FIG. 2 is a perspective view illustrating a configuration of a blade 6.

(3) FIG. 3 is a view of a blade holder 12 in a state where a root portion 8 of the blade 6 fits into a blade groove 10 as seen from a tip side of the blade 6 along a blade height direction.

(4) FIG. 4 is an A-A cross-sectional view in FIG. 3.

(5) FIG. 5 is a flowchart of an example of an electrical discharge machining method.

(6) FIG. 6 is a diagram for describing a step of positioning of the blade 6 in an extending direction of the blade groove.

(7) FIG. 7 is a diagram for describing a step of positioning of the blade 6 in a blade height direction and a width direction.

(8) FIG. 8 is a diagram for describing a step of fixing a blade holder 12 to a feed unit.

(9) FIG. 9 is a diagram for describing a step of immersing a portion 34 of the blade 6, which includes a machining object portion 32, in an electrical discharge machining liquid 11.

(10) FIG. 10 is a diagram for describing a step of applying a voltage between an electrode 14 and the blade 6.

(11) FIG. 11 is a diagram for describing the portion 34 of the blade 6 which immerses in the electrical discharge machining liquid 11 if the blade 6 is a turbine blade.

DETAILED DESCRIPTION

(12) Embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It is intended, however, that unless particularly identified, dimensions, materials, shapes, relative positions and the like of components described in the embodiments shall be interpreted as illustrative only and not intended to limit the scope of the present invention.

(13) For instance, an expression of relative or absolute arrangement such as “in a direction”, “along a direction”, “parallel”, “orthogonal”, “centered”, “concentric” and “coaxial” shall not be construed as indicating only the arrangement in a strict literal sense, but also includes a state where the arrangement is relatively displaced by a tolerance, or by an angle or a distance whereby it is possible to achieve the same function.

(14) For instance, an expression of an equal state such as “same” “equal” and “uniform” shall not be construed as indicating only the state in which the feature is strictly equal, but also includes a state in which there is a tolerance or a difference that can still achieve the same function.

(15) Further, for instance, an expression of a shape such as a rectangular shape or a cylindrical shape shall not be construed as only the geometrically strict shape, but also includes a shape with unevenness or chamfered corners within the range in which the same effect can be achieved.

(16) On the other hand, an expression such as “comprise”, “include”, “have”, “contain” and “constitute” are not intended to be exclusive of other components.

(17) FIG. 1 is a schematic view showing a schematic configuration of an electrical discharge machining device 2 according to an embodiment of the present invention.

(18) As shown in FIG. 1, the electrical discharge machining device 2 includes a feed unit 4, a blade holder 12 attached to the feed unit 4 and having a blade groove 10 into which a root portion 8 of a blade 6 (workpiece) is fittable, a container 13 accommodating an electrical discharge machining liquid 11, an electrode 14 immersed in the electrical discharge machining liquid in the container 13, and a power source 16 for applying a voltage between the blade 6 and the electrode 14. The blade 6 is a blade mounted on a rotor (not shown) of a rotary machine such as a gas turbine or a compressor, for example.

(19) The feed unit 4 is configured to move the blade holder 12 holding the blade 6 by a driving force of a motor, which is not shown, in three axial directions orthogonal to each other.

(20) The electrical discharge machining liquid 11 is a dielectric liquid filling a gap between the blade 6 and the electrode 14 in the electrical discharge machining device 2. The electrical discharge machining liquid 11 acts as an insulator, ionizes when a discharge occurs, and functions to maintain an electric field in which current flows. Further, the electrical discharge machining liquid 11 flowing through the gap serves to remove machining waste from the gap. For instance, a liquid containing water having a specific resistance adjusted to 1 to 10×10000 Ω.Math.cm or oil having extremely high specific resistance as a main component is preferably used for the electrical discharge machining liquid 11.

(21) A high electrically conductive material such as graphite and copper is preferably used for the electrode 14. Further, a pulse power source is preferably used for the power source 16. The upper surface 44 of the electrode 14 includes a curved concave surface shape as an inverted shape of the target shape of the blade tip surface 36.

(22) Next, the configuration of the blade 6 and the blade holder 12 as the workpiece will be described with reference to FIGS. 2 to 4. FIG. 2 is a perspective view illustrating the configuration of the blade 6. FIG. 3 is a view of the blade holder 12 in a state where the root portion 8 of the blade 6 fits into the blade groove 10 as seen from a tip side of the blade 6 along a blade height direction. FIG. 4 is an A-A cross-sectional view in FIG. 3.

(23) In an embodiment, as shown in FIG. 2 for instance, the blade 6 includes a blade profile 28 having a blade-shaped cross-sectional shape and the root portion 8 for mounting to the rotor, which is not shown. The root portion 8 has a width larger than a blade thickness of the blade profile 28. Herein, the “width” refers to a width in a direction orthogonal to each of the extending direction of the blade groove 10 and the blade height direction (hereinafter, referred to as width direction).

(24) In an embodiment, as shown in FIG. 4 for instance, the blade holder 12 includes a bolt 22 as a datum part for pressing the blade 6 toward the wall surface 20 such that the bearing surface 18 of the root portion 8 of the blade 6 is brought into contact with the wall surface 20 of the blade groove 10. The bearing surface 18 is a surface coming into contact with the rotor, which is not shown, when the blade 6 is mounted on the rotor.

(25) Further, as shown in FIG. 4 for instance, the bearing surface 18 of the typical blade 6 extends obliquely with respect to the blade height direction. Thus, as described above, if the bearing surface 18 of the root portion 8 is brought into contact with the wall surface 20 of the blade groove 10, the blade 6 is positioned with respect to not only the blade height direction but also the width direction of the root portion 8 of the blade 6. Accordingly, it is possible to improve accuracy of electrical discharge machining.

(26) Further, in the embodiment shown in the drawings, a pair of the bearing surfaces 18 is formed in the root portion 8. The pair of bearing surfaces 18 is inclined with respect to the blade height direction so that the interval between the pair of bearing surfaces 18 becomes narrow toward the blade tip side. Further, a pair of wall surfaces 20 contacting with the pair of bearing surfaces 18 is formed in the blade groove 10. The pair of wall surfaces 20 is inclined with respect to a depth direction of the blade groove 10 (blade height direction) so that the interval between the pair of wall surfaces 20 becomes narrow toward an opening side of the blade groove 10 (blade tip side).

(27) In an embodiment, as shown in FIGS. 3 and 4, the electrical discharge machining device 2 further comprises a datum block 26 configured to be at least partially inserted into the blade groove 10 of the blade holder 12 such that one end face 24 of the root portion 8 of the blade 6 in the extending direction of the blade groove 10 is brought into contact with the datum block 26. In the depicted illustrative embodiment, the datum block 26 is fixed to the blade holder 12 by a plurality of bolts 30.

(28) With the above configuration, the one end face 24 of the root portion 8 of the blade 6 is brought into contact with the datum block 26, then the blade 6 can be positioned with respect to the extending direction of the blade groove 10. Accordingly, it is possible to improve accuracy of electrical discharge machining.

(29) Next, with reference to FIGS. 5 to 10, an example of an electrical discharge machining method for machining the blade 6 as the workpiece described above by the electrical discharge machining device 2 will be described.

(30) First, in step S1, as shown in FIG. 6, the root portion 8 of the blade 6 is inserted into the blade groove 10 of the blade holder 12, and one end face 24 of the root portion 8 of the blade 6 in the extending direction of the blade groove 10 is brought into contact with the datum block 26. Thus, the blade 6 can be positioned relative to the blade holder 12 with respect to the extending direction of the blade groove 10.

(31) Next, in step S2, as shown in FIG. 7, the blade 6 is pressed by the bolt 22 provided in the blade holder 12 such that the bearing surface 18 of the root portion 8 is brought into contact with the wall surface 20 of the blade groove 10. Thus, the blade 6 can be positioned relative to the blade holder 12 with respect to the blade height direction and the width direction.

(32) Next, in step S3, as shown in FIG. 8, the blade 6 is attached to the feed unit 4 via the blade holder 12 by fixing the blade holder 12 to the feed unit 4 of the electrical discharge machining device 2.

(33) Next, in step S4, as shown in FIG. 9, only the portion 34 of the blade 6 which includes the machining object portion 32 is selectively immersed in the electrical discharge machining liquid 11 such that a lower surface 46 (blade tip surface 36 in the depicted embodiment) of the machining object portion 32 of the blade 6 is opposed to an upper surface 44 of the electrode 14 immersed in the electrical discharge machining liquid 11. That is, in step S4, the feed unit 4 makes the blade 6 approach the electrode 14 from above the electrode such that the lower surface 46 of the machining object portion 32 of the blade 6 is opposed to the upper surface 44 of the electrode 14 while the electrode 14 is kept stationary. In the illustrated example, only the portion 34 on the tip side of the blade 6 relative to the root portion 8 is immersed in the electrical discharge machining liquid.

(34) Next, in step S5, as shown in FIG. 10, the electrical discharge machining is performed on the machining object portion 32 by applying the voltage between the electrode 14 and the blade 6 in a state where the portion 34 described above of the blade 6 is selectively immersed in the electrical discharge machining liquid 11. In the illustrated example, the electrical discharge machining is performed on the blade tip surface 36 as the machining object portion 32 of the blade 6. Accordingly, the blade tip surface 36 is machined into a curved convex shape as an inverted shape corresponding to a curved concave shape of the upper surface 44 of the electrode 14.

(35) According to the electrical discharge machining method described above, the electrical discharge machining is performed in a state where the only portion 34 of the blade 6, which includes the machining object portion 32, as the workpiece is selectively immersed in the electrical discharge machining liquid 11, thus, it is possible to reduce time and cost required for the cleaning process of the blade 6 after the electrical discharge machining.

(36) Further, the method is different from the typical electrical discharge machining method, the blade 6 instead of the electrode is attached to the feed unit 4 of the electrical discharge machine device 2 so that the blade 6 is capable of moving. Then, it is possible to easily realize the electrical discharge machining in a state where only the portion 34 described above of the blade 6 is selectively immersed in the electrical discharge machining liquid 11. Accordingly, it is possible to easily reduce time and cost required for the cleaning process of the blade 6 after the electrical discharge machining.

(37) Further, performing the electrical discharge machining on the blade tip surface 36 of the desired shape as the machining object portion 32 does not require the above-described curing operation needed for performing the grinding process which is a typical machining method for the blade tip surface 36. Thus, it is possible to reduce time and cost required for machining the blade tip surface 36.

(38) Further, when a coating is applied to the bearing surface 18 of the root portion 8 of the blade 6 for the purpose of preventing seizure, it is not necessary for cleaning the root portion 8 by not immersing the root portion 8 in the electrical discharge machining liquid 11.

(39) In an embodiment, the blade 6 as the workpiece may be a rotor blade of a downstream stage of a compressor of a gas turbine which is not shown.

(40) In this case, since the compressor rotor blade of the downstream stage which is comparatively light-weight is used as the processing object, the blade 6 can be attached to the feed unit 4 of the electrical discharge machine device 2 while satisfying constraints caused by specifications of the electrical discharge machining device 2. Further, the blade 6 is attached to the feed unit 4 of the electrical discharge machine device 2, thus, it is possible to easily realize the electrical discharge machining in a state where only the portion 34 of the blade 6 which includes the machining object portion 32 is selectively immersed in the electrical discharge machining liquid 11.

(41) In an embodiment, the blade 6 as the workpiece may be a turbine blade of a gas turbine. In this case, as shown in FIG. 11, the electrical discharge machining may be performed on the blade tip surface 36 while only the tip portion of the blade 6 as the portion 34 which includes the machining object portion 32 is immersed in the electrical discharge machining liquid 11 so as not to prevent the electrical discharge machining liquid 11 from entering a cooling hole 42 provided on the blade profile 38 or the platform 40 of the blade 6.

(42) The present invention is not limited to the embodiments described above, but includes embodiments composed of variations of the embodiments described above, and embodiments composed of proper combinations of those embodiments.

(43) For instance, in the electrical discharge machining method described above, while a case where the electrical discharge machining is performed on the blade tip surface 36 is described as an example, the present invention is applicable to a case of performing the electrical discharge machining on the machining object portion other than the blade tip surface and is applicable to a case where the electrical discharge machining is performed on the workpiece other than the blade.

(44) That is, in an embodiment, the method may comprise: a step of selectively immersing only the portion of the workpiece, which includes the machining object portion, in the electrical discharge machining liquid such that the machining object portion of the workpiece is opposed to the electrode immersed in the electrical discharge machining liquid and a step of applying the electrical discharge machining to the machining object portion by applying the voltage between the electrode and the workpiece in a state where the portion of the workpiece, which includes the machining object portion, is selectively immersed in the electrical discharge machining liquid.

(45) In this way, since the electrical discharge machining is performed in a state where only the portion of the workpiece, which includes the machining object portion, is selectively immersed in the electrical discharge machining liquid, it is possible to reduce time and cost required for the cleaning process of the workpiece after the electrical discharge machining.

REFERENCE SIGNS LIST

(46) 2 Electrical discharge machining device 4 Feed unit 6 Blade 8 Root portion 10 Blade groove 11 Electrical discharge machining liquid 12 Blade holder 13 Container 14 Electrode 16 Power source 18 Bearing surface 20 Wall surface 22 Bolt 24 End face 26 Datum block 28 Blade profile 32 Machining object portion 34 Portion 36 Blade tip surface 38 Blade profile 40 Platform 42 Cooling hole 44 Upper surface 46 Lower surface