A hybrid machining center for enabling new die manufacturing and repair concepts

Brecher, Christian; Klocke, Fritz; Breitbach, Tobias; Do-Khac, Dennis; Heinen, Daniel; Karlberger, Andreas; Rosen, Chris-Jörg

doi:10.1007/s11740-011-0323-0

Cited by 9 publications

(3 citation statements)

References 6 publications

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“…The aim of the recontouring stage is to remove, by machining operations, the excess material added in the welding stage (see Figure 1a,b) using additive manufacturing technologies such as laser cladding [5] or laser metal deposition [6] and achieve the final blade geometry. Although these operations have traditionally been performed through manual belt grinding, the need to automate the process to the extent possible has encouraged the engine part maintenance industry to move towards milling-based recontouring (see Figure 1c), performed on 5-axis machines or hybrid cells in which welding and machining operations are performed in the same clamping [7,8].…”

Section: Introductionmentioning

confidence: 99%

Self-Tuning Algorithm for Tuneable Clamping Table for Chatter Suppression in Blade Recontouring

et al. 2021

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The production and repair of blades for aerospace engines and energy turbines is a complex process due their inherently low stiffness and damping properties. The final recontouring operation is usually performed by milling operations where regenerative chatter is one of the main productivity limiting factors. With the objective of avoiding specific stiffening fixtures for each blade geometry, this paper proposes a semi-active tuneable clamping table (TCT) based on mode tuning for blade machining. The active mode of the device can be externally controlled by means of a rotary spring and eddy current damping modules. Its in-series architecture allows damping to be introduced to the critical mode of the thin-walled part without any direct contact in the machining area and enables a more universal clamping. Its chatter suppression capabilities are maximized by means of a novel self-tuning algorithm that iteratively optimizes the tuning for the measured chatter frequency. The benefits of the iterative algorithm are validated through semidiscretization and initial value time-domain simulations, showing a clear improvement in blade recontouring stability compared to regular broad-bandwidth tuning methods.

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Section: Introductionmentioning

confidence: 99%

Self-Tuning Algorithm for Tuneable Clamping Table for Chatter Suppression in Blade Recontouring

et al. 2021

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“…Repairing these parts extends the mentioned challenges due to unique part characteristics. New machining strategies, cutting tools but also machine tools or components have to be developed to successfully overcome the difficulties [1,2].…”

Section: Introductionmentioning

confidence: 99%

Conceptual Design for Electromagnetic Guided Rotary Table in Machine Tools

et al. 2014

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Difficult-to-machine materials are still challenging the production industry. Examples are highly complex components of aircraft engines. Alongside innovative processes, also improved machine tool components are helping to comply with the demands of this task. This paper presents a design approach of a rotary table with an active magnetic bearing. Opportunities in machining through employing magnetic guides are presented and discussed in the beginning. In the following, a workflow for the magnetic bearing design in swivel rotary tables is proposed. The mentioned steps are executed based on a presently under design rotary table.

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“…Yilmaz developed a machining strategy including the correct choice of tool and milling method [3]. Instead of using a conventional machine tool, Brecher presented a hybrid machining center, which combines material deposit and re-contouring [6]. Huang proposed the use of robots as more flexible alternative to machine tools [7].…”

Section: Introductionmentioning

confidence: 99%

Approaches for Improving Cutting Processes and Machine Tools in Re-contouring

et al. 2014

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Re-contouring in the repair process of aircraft engine blades and vanes is a crucial task. Highest demands are made on the geometrical accuracy as well as on the machined surface of the part. Complexity rises even more due to the unique part characteristic originating from the operation and repair history. This requires well-designed processes and machine tool technologies. In this paper, approaches for coping with these challenges and improving the re-contouring process are described and discussed. This includes an advanced process simulation with its capabilities to accurately depict different material areas and predict process forces. Beyond, experimental investigations on workpiece-tooldeflection are presented. Finally, a machine tool prototype with a novel electromagnetic guiding system is introduced and the benefits of this technology in the field of repair are outlined.

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A hybrid machining center for enabling new die manufacturing and repair concepts

Cited by 9 publications

References 6 publications

Self-Tuning Algorithm for Tuneable Clamping Table for Chatter Suppression in Blade Recontouring

Self-Tuning Algorithm for Tuneable Clamping Table for Chatter Suppression in Blade Recontouring

Conceptual Design for Electromagnetic Guided Rotary Table in Machine Tools

Approaches for Improving Cutting Processes and Machine Tools in Re-contouring

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