【摘要】：現(xiàn)如今,隨著常規(guī)能源的日益匱乏和環(huán)境的不斷惡化,清潔無污染的水能資源受到了世界各國的認可與青睞。同時水利發(fā)電技術成熟、成本低、可再生,有助于緩解各國用電緊張的問題,因此許多國家都不得不加快水利水電開發(fā)的步伐�？梢韵胂�,水利發(fā)電將逐步取代傳統(tǒng)的發(fā)電方式成為發(fā)電行業(yè)的主流。 水輪機是水力發(fā)電必不可少的原動機,轉輪葉片又是水輪機的核心部件,因此,轉輪葉片的制造質量和精度直接影響著水力發(fā)電機組安全準確,平穩(wěn)高效的運行。水輪機轉輪葉片是非常復雜的雕塑曲面體,傳統(tǒng)的“砂型鑄造——砂輪鏟磨——立體樣板檢測”的制造工藝,并不能很好保證葉片的加工精度和質量。近年來,水輪機制造業(yè)一直探索采用五軸聯(lián)動數(shù)控加工的方法制造大型葉片,但在采用該方法制造葉片時,仍然采用試加工的方式來檢驗和修正NC程序,致使葉片的制造周期長、效率低。而數(shù)字化加工仿真技術可以在計算機上模擬出零件切削的全過程,能較好的解決上述問題。 本文以計算機輔助幾何設計,數(shù)控加工仿真技術、軟件的二次開發(fā)技術等理論作為依據(jù),以某大型混流式水輪機葉片為研究對象,首先完成了葉片和相應加工機床的三維幾何造型,葉片的五坐標數(shù)控加工刀位軌跡規(guī)劃計算及其后置處理。在此基礎上,構建了葉片的數(shù)字化加工仿真環(huán)境,并進行了葉片的數(shù)字化加工幾何仿真。最后在對專業(yè)軟件進行二次開發(fā)的基礎上探索出一種將數(shù)控幾何仿真和物理仿真相結合的數(shù)值模擬方法,實現(xiàn)了大型混流式水輪機葉片的五坐標數(shù)字化加工仿真和切削力模擬仿真,優(yōu)化了切削參數(shù),提高了葉片的加工質量。 本論文研究成果不僅可用于描述仿真加工過程的空間幾何運動,用于模擬葉片材料的切除過程,預測加工過程的表現(xiàn)、加工質量和加工效率。該成果可作為大型復雜葉片的多軸聯(lián)動數(shù)控加工輔助編程的有效手段,代替實物試切削或試加工過程,大大地降低制造成本,保證加工過程中工藝系統(tǒng)的安全,對于推動水力發(fā)電設備制造業(yè)技術進步有重要意義。
[Abstract]:Nowadays, with the increasing shortage of conventional energy and the deterioration of the environment, clean and pollution-free water energy resources have been recognized and favored by all countries in the world. At the same time, the technology of hydropower generation is mature, the cost is low and renewable, which helps to alleviate the problem of electricity shortage in various countries, so many countries have to speed up the pace of water conservancy and hydropower development. It can be imagined that hydropower will gradually replace the traditional power generation method as the mainstream of the power generation industry. Hydraulic turbine is an indispensable prime mover for hydropower generation, and runner blade is the core component of hydraulic turbine. Therefore, the manufacturing quality and accuracy of turbine blade directly affect the safe, accurate, stable and efficient operation of hydropower unit. The turbine runner blade is a very complex sculptural curved body. The traditional manufacturing technology of "sand mold casting-grinding wheel shovel grinding-three-dimensional template detection" can not guarantee the machining accuracy and quality of the blade. In recent years, the hydraulic turbine manufacturing industry has been exploring the method of five-axis linkage NC machining to manufacture large blades, but when using this method to manufacture blades, it still adopts the way of trial machining to test and modify the NC program. As a result, the manufacturing cycle of the blade is long and the efficiency is low. The digital machining simulation technology can simulate the whole process of part cutting on the computer, and can solve the above problems. In this paper, based on the theories of computer aided geometric design, NC machining simulation technology and software secondary development technology, the blade of a large Francis turbine is taken as the research object. Firstly, the 3D geometric modeling of the blade and the corresponding machining machine tool, the five-axis NC machining tool path planning calculation and the post-processing of the blade are completed. On this basis, the digital machining simulation environment of the blade is constructed, and the digital machining geometry simulation of the blade is carried out. Finally, on the basis of the secondary development of professional software, a numerical simulation method combining numerical control geometric simulation and physical simulation is explored. The five-coordinate digital machining simulation and cutting force simulation of large Francis turbine blade are realized, the cutting parameters are optimized and the machining quality of the blade is improved. The research results of this paper can be used not only to describe the spatial geometric motion of the simulated machining process, but also to simulate the removal process of blade materials, and to predict the performance, machining quality and machining efficiency of the machining process. This result can be used as an effective means of multi-axis linkage NC machining auxiliary programming for large and complex blades, replacing the physical cutting or trial machining process, greatly reducing the manufacturing cost and ensuring the safety of the process system in the machining process. It is of great significance to promote the technological progress of hydropower equipment manufacturing industry.
【學位授予單位】：昆明理工大學
【學位級別】：碩士
【學位授予年份】：2014
【分類號】：TK730.6

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