CAD/CAM solutions for efficient machining of turbo machinery components by Sturz milling method

Madhavulu, G.; Sundar, Shanmuga; Ahmed, Baqer Ayad

doi:10.1109/iecon.1996.570604

Cited by 8 publications

(5 citation statements)

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“…In the Sturz milling method (Tigran and Schnider, 2001), a constant Sturz angle (an inclined tool axis angle in the direction of the milling path) to machine a surface, or a tilt angle (angle between tool axis in the milling direction and perpendicular to the milling direction) is used for machining of blade surfaces. In general, it gives a more feasible or cost‐effective solution for the production of turbomachinery components (Madhavulu et al , 1996). It is claimed that the resulting milling path widths are for general freeform surface cases, relatively far from the optimum.…”

Section: Machining Methods Of Bladesmentioning

confidence: 99%

A study of turbomachinery components machining and repairing methodologies

Yilmaz

Noble

Gindy

et al. 2005

Aircraft Engineering and Aerospace Technology

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PurposeThis paper discusses research on machining and repairing of turbomachinery components which are generally complex geometries and made up of difficult to machine materials (nickel super alloys or titanium alloys).Design/methodology/approachThe approaches, methods and methodologies used for machining and repairing of blades are reviewed as well as the comparisons between them are made.FindingsParticularly, the most recent blade machining and repair techniques using high flexible machine tools and industrial robots, are mentioned.Practical implicationsThe limitation of the approaches, methods and methodologies are given and supported by real practical application examples.Originality/valueThis paper presents a state of the art review of research in machining and repairing of turbomachinery components, which have been mainly done in the last decade. The paper act as a reference, gathering the works about turbomachinery components from a manufacturing point of view.

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Section: Machining Methods Of Bladesmentioning

confidence: 99%

A study of turbomachinery components machining and repairing methodologies

Yilmaz

Noble

Gindy

et al. 2005

Aircraft Engineering and Aerospace Technology

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show abstract

“…Such a strategy to mill the two surfaces of a blade together was also proposed by Madhavulu et al [11] in 1996. In their work a Kaplan blade was machined with spiral tool paths generated by using a template of Unigraphics.…”

Section: Introductionmentioning

confidence: 92%

“…In addition, high-efficiency machining of turbine blades requires the two opposite sides of one blade to be machined continuously in the same operational step of processing each individual blade [10]. Such a strategy to mill the two surfaces of a blade together was also proposed by Madhavulu et al [11] in 1996. In their work a Kaplan blade was machined with spiral tool paths generated by using a template of Unigraphics.…”

Section: Introductionmentioning

confidence: 99%

Boundary-conformed machining of turbine blades

Ding

Yang

Han

2005

Proceedings of the Institution of Mechanical Engineers, Part B:

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Boundary-conformed machining is a new method to mill free-form surfaces with tool paths that reflect the natural shapes of the surfaces. It is suitable for the machining of turbine blades taking into account the direction of tool marks left on the vanes. To facilitate this type of machining, this paper introduces an application of the 'boundary-conformed algorithm' to generate continuous boundary-conformed flow line tool paths for the milling of blade surfaces. With this approach, the initial segment of the flow line tool paths is along the top edges of the blade while the final segment follows the intersection curves between the blade and the hub surface. The intermediate segments cover the surface by changing smoothly from the initial tool path to the final tool path. The two opposite sides of the blade, which are two trimmed surfaces, are machined together continuously from top to bottom with these continuous boundary-conformed tool paths. This method has been successfully integrated into an industrial computer-aided design and manufacture system (Pro/Engineer) by using Pro/Toolkit. A detailed algorithm and implementation processes have been introduced.

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“…However, the previously mentioned methods are global optimization for the 5-axis toolpath and usually use iterative algorithm 2,3,12 or nonlinear programming method 11 to conduct the optimization solution. Due to the efficient topology, 13 the spiral contouring toolpath is the most commonly utilized path mode for the abrupt curvature parts machining, such as turbine blade and fixed guide vane. In this path mode, the surface of machined parts is enveloped by only one continuous spiral curves containing tens of thousands or more discrete tool positions in the surface finish machining stages.…”

Section: Introductionmentioning

confidence: 99%

An efficient 5-axis toolpath optimization algorithm for machining parts with abrupt curvature

Qin

Zhang

et al. 2015

Proceedings of the Institution of Mechanical Engineers, Part C:

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The kinematical behavior of 5-axis machine tool introduced by toolpath calculation has a close relation with processing efficiency and quality of parts. For the category of sculptured surface parts with abrupt curvature, such as turbine blade and fixed guide vane, the most commonly utilized spiral contouring toolpath modes usually encounter some trouble during actual machining, the reason lies in the difficult tool orientation control near the edge of such parts. However, the global optimization for the spiral toolpath means increased computation burden, and so it is time consuming. In this paper, an efficient 5-axis toolpath optimization algorithm is presented, and the objective is to smooth the rotary axes’ motion caused by drastically changed tool orientation on spiral toolpath for abrupt curvature parts machining. To reduce the computation burden, only path segments on the spiral trajectory-owned weak kinematic performance are selected for further optimizing. To obtain smoother motion for rotary axes, the specific optimization computation for the selected path segments is conducted in the Machine Coordinate System (MCS) instead of the Part Coordinate System (PCS). The optimization model is constructed and a related solution method is presented to ensure the high-performance optimization. The complete optimization algorithm is demonstrated on a spiral 5-axis toolpath for the turbine blade finish machining, and the result shows that only 25.9% optimization computation is needed compared with global optimization algorithm. And then, the actual machining experiments are carried out by using paraffin as cut material, and the machining time with optimized toolpath is decreased by 19.7% compared with initial toolpath. In addition, the surface quality of parts is significantly improved after conducting the optimization. This study proves that the proposed algorithm can significantly improve the processing efficiency and surface quality of parts with abrupt curvature and provides an efficient method to optimize the spiral 5-axis toolpath used for finish machining parts with abrupt curvature.

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CAD/CAM solutions for efficient machining of turbo machinery components by Sturz milling method

Abstract: Rapid developments in the fields of engineering and

Cited by 8 publications

References 0 publications

A study of turbomachinery components machining and repairing methodologies

A study of turbomachinery components machining and repairing methodologies

Boundary-conformed machining of turbine blades

An efficient 5-axis toolpath optimization algorithm for machining parts with abrupt curvature

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