Magnetorheological support method for blisk processing

A magnetorheological support method for blisk processing, using a fork structure and a soft film to wrap magnetorheological fluid, wherein the magnetorheological fluid is used for flow filling under certain pressure;

• the bulged soft film can conduct shape matching on the surface of a blisk blade;
• the magnetorheological fluid can be cured through magnetic field excitation, thereby ensuring the flexible support for a weak rigid component;
• electric permanent magnets are symmetrically arranged at both ends of the fork structure to construct a uniform magnetic field that can realize a global excitation of magnetorheological fluid, so that the magnetorheological fluid works in a shear mode to achieve damping force controlling by magnetic field;
• the solid-liquid conversion of the magnetorheological fluid is controlled by an electric permanent magnet field;
• automatic magnetorheological flexible support of all blades is realized in the processing of the blisk blade through the automatic dividing of an indexing turntable and the automatic transportation of a magnetorheological soft film;
• specific steps of the method are as follows:
• step 1, assembling a magnetorheological fluid supporting device
• the magnetorheological fluid supporting device is composed of two parts:
• a linear feed mechanism and a magnetorheological support;
• firstly, installing the linear feed mechanism;
• installing two linear guides on a fixing bench;
• then installing a sliding seat on the two linear guides;
• fastening a screw bracket on the fixing bench by using a screw;
• installing a support frame on a T groove of the sliding seat by using a T bolt;
• installing one end of the ball screw in the screw bracket, and installing the other end of the ball screw in a motor base on the fixing bench;
• connecting a motor with the ball screw through a coupling;
• then, installing the magnetorheological support which is composed of a skeleton, a permanent magnet, a soft film and a pipe clamp which are installed on the support frame, as well as a peristaltic pump and magnetorheological fluid;
• wrapping the soft film outside a skeleton so that the soft film is in close fitting with the edge of the permanent magnet;
• sealing the soft film on a cylinder by using a pipe clamp for hold rubber tubing;
• arranging a magnetorheological fluid channel in the cylinder and a crossbeam connected with the cylinder;
• leading one end of the magnetorheological fluid channel to the interior of the soft film, and connecting the other end with the peristaltic pump;
• and connecting the peristaltic pump with the magnetorheological fluid;
• step 2 placing a blisk on a three jaw chuck of a NC rotary table to complete positioning clamping;
• during clamping, appropriately adjusting the height and the angle of the NC rotary table so that two blades on the outermost side of the blisk adapt to the location of the magnetorheological support;
• step 3 moving the magnetorheological support to a suitable location between the two blades and by using the linear feed mechanism;
• turning on a switch of the peristaltic pump;
• filling the magnetorheological fluid into the soft film under certain pressure;
• allowing the soft film to generate elastic bulging and shape matching with the contour of the blade;
• and completing the sealing of the magnetorheological fluid by using the pipe clamp;
• step 4 turning on the switch of the permanent magnet;
• conducting excitation curing for the magnetorheological fluid in the soft film;
• keeping the current shape of the soft film to realize conformal flexible support for the surface on one side of the blade;
• controlling, by a numerical control machine, a milling cutter to process the other side shape of the blade (3a) to be processed;
• after completing the processing of the current supported blade, turning off a control switch of the permanent magnet;
• an excitation magnetic field disappearing;
• and restoring the magnetorheological fluid in the soft film to the liquid state;
• step 5 controlling the peristaltic pump to pump out the magnetorheological fluid so that the volume of the soft film is reduced;
• moving the magnetorheological support through the linear feed mechanism to separate from the blisk;
• rotating the blisk through the NC rotary table by a certain angle to rotate the next blade to a processing station;
• and continuously repeating the above steps to realize the magnetorheological flexible support in the processing of all the blisk blades.