Method for producing integrally bladed rotors

Abstract

A method for producing integrally bladed rotors comprises the following steps: a) defining and providing a blade profile of a blade to be manufactured with a pre-contour and a theoretical contour; b) producing at least two sectional planes of the blade profile, which sectional planes run vertically to a threading axis of the blade profile and of the blade to be manufactured; c) determining a point of rotation per sectional plane to produce an interval between the pre-contour and the theoretical contour that is approximately the same circumferentially, which points of rotation are located on a connecting line running parallel to the threading axis; and d) providing a base rotor body and electrochemically working the base rotor body in order to produce a raw blade with the blade pre-contour by movement of a hollow electrode into the base rotor body, the electrode movement including advancing motion along the connecting line superposed by rotation at the points of rotation, and which hollow electrode has an inner contour adapted to the pre-contour of the raw blade at least in an end area that is moved into the base rotor body.

1 - 11 . (canceled) 
     
     
         12 . A method for producing integrally bladed rotors, the method comprising the following steps:
 a) defining and providing a blade profile of a blade to be manufactured with a pre-contour and a theoretical contour;   b) producing at least two sectional planes of the blade profile, which sectional planes run vertically to a threading axis of the blade profile and of the blade to be manufactured;   c) determining a point of rotation per sectional plane to produce an interval between the pre-contour and the theoretical contour that is approximately the same circumferentially, which points of rotation are located on a connecting line running parallel to the threading axis; and   d) providing a base rotor body and electrochemically working the base rotor body in order to produce a raw blade with the blade pre-contour by movement of a hollow electrode into the base rotor body, the electrode movement including advancing motion along the connecting line superposed by rotation at the points of rotation, and which hollow electrode has an inner contour adapted to the pre-contour of the raw blade at least in an end area that is moved into the base rotor body.   
     
     
         13 . A method in accordance with  claim 12 , wherein a plurality of hollow electrodes is moved simultaneously or successively into the base rotor body. 
     
     
         14 . A method in accordance with  claim 13 , wherein prior to moving each of the plurality of hollow electrodes, a respective connecting line is determined along which the advancing motion of the respective hollow electrode takes place. 
     
     
         15 . A method in accordance with  claim 12 , wherein the points of rotation are arranged off-center relative to the blade profile. 
     
     
         16 . A method in accordance with  claim 12 , wherein during the step of providing a base rotor body and electrochemically working the base rotor body, a pre-allocation of intermediate spaces between two adjacent raw blades takes place. 
     
     
         17 . A method in accordance with  claim 12 , wherein the hollow electrode is constructed in an electrically insulating manner except for an end area that is moved into the base rotor body. 
     
     
         18 . A method in accordance with  claim 12 , further comprising:
 e) electrochemically working the raw blade having the blade pre-contour to produce a blade having fluidic surfaces corresponding to the theoretical contour.   
     
     
         19 . A method in accordance with  claim 18 , wherein the electrochemical working of the raw blade having the blade pre-contour is performed using a precise electrochemical removal process (PECM). 
     
     
         20 . A method in accordance with  claim 19 , wherein during the electrochemical working of the raw blade having the blade pre-contour, at least one of an inner contour and an outer contour of at least one electrode is adapted to the theoretical contour of the blade. 
     
     
         21 . A method in accordance with  claim 19 , wherein during the electrochemical working of the raw blade having the blade pre-contour, the electrode executes oscillating movements. 
     
     
         22 . A method for integrally forming a raw blade having a pre-contour on a base rotor body for which a blade profile including a threading axis, a raw blade pre-contour and a blade theoretical contour have been defined, the method comprising the steps:
 providing a base rotor body for which a blade profile including a threading axis, a raw-blade pre-contour and a blade theoretical contour have been defined;   providing a hollow electrode having an inner contour configured to the raw blade pre-contour at least in an end area;   defining a plurality of sectional planes of the blade profile, the sectional planes being spaced apart along the threading axis;   determining a point of rotation for each sectional plane, each point of rotation constituting a point at which the hollow electrode is to be rotated to produce a substantially uniform overmeasure between the respective pre-contour and the respective theoretical contour of the sectional plane, the points of rotation defining a connecting line; and   electrochemically working the base rotor body while moving the end area of the hollow electrode into the base rotor body with an advancing motion along the connecting line superposed by rotation at the points of rotation;   whereby a raw blade with the blade pre-contour is produced, the pre-contour having a substantially uniform overmeasure with respect to the theoretical contour.   
     
     
         23 . A method in accordance with  claim 22 , wherein the points of rotation are arranged off-center relative to the blade profile. 
     
     
         24 . A method in accordance with  claim 22 , wherein the hollow electrode is constructed in an electrically insulating manner except for the end area. 
     
     
         25 . A method for integrally forming a blade on a base rotor body for which a blade profile including a threading axis, a raw blade pre-contour and a blade theoretical contour have been defined, the method comprising the steps:
 providing a base rotor body for which a blade profile including a threading axis, a raw-blade pre-contour and a blade theoretical contour have been defined;   providing a hollow electrode having an inner contour configured to the raw blade pre-contour at least in an end area;   defining a plurality of sectional planes of the blade profile, the sectional planes being spaced apart along the threading axis;   determining a point of rotation for each sectional plane, each point of rotation constituting a point at which the hollow electrode is to be rotated to produce a substantially uniform overmeasure between the respective pre-contour and the respective theoretical contour of the sectional plane, the points of rotation defining a connecting line;   electrochemically working the base rotor body while moving the end area of the hollow electrode into the base rotor body with an advancing motion along the connecting line between each point of rotation;   rotating the electrode at each point of rotation while continuing to electrochemically work the base rotor body and advancing along the connecting line until a raw blade with the blade pre-contour is produced, the pre-contour having a substantially uniform overmeasure with respect to the theoretical contour; and   electrochemically working the raw blade having the blade pre-contour using an electrode wherein at least one of an inner contour and an outer contour is configured to the theoretical contour of the blade;   whereby a blade having fluidic surfaces substantially corresponding to the theoretical contour is integrally produced on the base rotor body.   
     
     
         26 . A method in accordance with  claim 25 , wherein the electrode used to produce the raw blade having the pre-contour and the electrode used to produce the blade have the theoretical contour are the same electrode. 
     
     
         27 . A method in accordance with  claim 25 , wherein the electrode used to produce the raw blade having the pre-contour and the electrode used to produce the blade have the theoretical contour are different electrodes. 
     
     
         28 . A method in accordance with  claim 25 , wherein during the electrochemical working of the raw blade having the blade pre-contour, the electrode executes oscillating movements. 
     
     
         29 . A method in accordance with  claim 25 , wherein the points of rotation are arranged off-center relative to the blade profile. 
     
     
         30 . A method in accordance with  claim 25 , wherein the hollow electrode is constructed in an electrically insulating manner except for the end area. 
     
     
         31 . A method in accordance with  claim 25 , wherein the electrochemical working of the raw blade having the blade pre-contour is performed using a precise electrochemical removal process (PECM).