Edge finishing of large turbine casings using defined multi-edge and abrasive tools in automated cells

Rodríguez, Adrián; González, M. C.; Pereira, Octavio; Lacalle, Luis Norberto López de; Esparta, Mikel

doi:10.1007/s00170-021-08087-y

Cited by 21 publications

(7 citation statements)

References 25 publications

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“…The removal of burrs will require the use of deburring processes after the end of the milling process. For this reason, introducing deburring methods involving the help of robots could prove an effective solution for reducing the duration of manufacturing products incorporating thin walls [ 66 ].…”

Section: Methodsmentioning

confidence: 99%

Evaluation of Thin Wall Milling Ability Using Disc Cutters

et al. 2023

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In some cases, industrial practice requires the production of walls or parts with a thickness of less than one millimeter from a metal workpiece. Such parts or walls can be made by milling using disc cutters. This machining method can lead to the generation of residual stresses that determine the appearance of a form deviation characterized by bending the part or the thin wall. To evaluate the suitability of a metallic material for the manufacturing of thin walls by milling with disc cutters, different factors capable of exerting influence on the deviation generated by the residual deformation of the walls were taken into account. A test sample and an experimental research program were designed for the purpose of obtaining an empirical mathematical model. The empirical mathematical model highlights the magnitude of the influence exerted by different input factors on the disc cutter milling process regarding the size of the deviation from the form, and the correct position of the wall or thin part, in the case of a test sample workpiece made of an aluminum alloy. Input factors considered were cutting speed, feed rate, cutter thickness, wall or part thickness, thin wall length, and height. To rank the input factors whose increase leads to an increase in shape deviation, the values of the exponents attached to the factors in question in the empirical mathematical model of the power-type function were taken into account. It was found that the values of the exponents are in the order 0.782 > 0.319 > 0.169 for wall height, feed rate, and wall width, respectively. It was thus established that the strongest influence on the residual deformation of the thin wall is exerted by its height.

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Section: Methodsmentioning

confidence: 99%

Evaluation of Thin Wall Milling Ability Using Disc Cutters

et al. 2023

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“…In order to improve the automation level of ultrasonic strengthening and realize the high precision strengthening of the blade surface, it is necessary to apply an industrial robot with a strengthening device to complete the process automatically. The advantages of industrial robots in the field of automated processing are very prominent, for example, a robotic complete finishing process is introduced for automated robotic deburring applications with low machinability materials on aero-engine casings with complex geometries [10], thus enabling a reduction in process operating time and improving processing quality. In the process of ultrasonic strengthening of the blade surface, the contact force between the strengthening tool and the workpiece surface is very important for forming a residual stress layer [11,12].…”

Section: Introductionmentioning

confidence: 99%

Process Optimization for Robotic Ultrasonic Strengthening of Aviation Blade Surfaces Based on Intelligent Compliance Control

Fang,

Zhu,

Zhang

et al. 2023

Micromachines

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In order to enhance the automation level and achieve high precision in the ultrasonic strengthening of aviation blade surfaces, this study focuses on investigating the intelligent control strategy and optimizing the machining parameters for robotic ultrasonic surface strengthening. By designing an intelligent compliance control method, the end-effector can achieve the compliant output of contact force. The fuzzy PID control method is used to optimize the regulation performance of the compliant force control system. This compliance control strategy enables the optimization of the compliance device, effectively improving the static and dynamic characteristics of the compliance controller. Based on this, an experimental method (RSM) is designed to analyze the interaction effects of contact force, feed rate, and repetition times on the surface quality of the blade. The optimal combination of robotic strengthening parameters is determined, providing a practical reference for the application of robotic compliance control in the ultrasonic strengthening of aviation blade surfaces.

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“…18 From the literature review, it is found that researchers have utilized viscoelastic nature of the tool material for different finishing processes. The flexible tools reported by Rodrı´guez et al 19 is mainly based upon brush technology where abrasive balls of different sizes and materials are attached on top of the nylon filament. These types of tools are commonly used in finishing of internal holes, deburring, and blending of the edges.…”

Section: Introductionmentioning

confidence: 99%

Finishing of OFHC copper using fluid filled open-cell porous flexible abrasive impregnated tools

Kumar

Sidpara

Racherla

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Super finishing of oxygen-free high thermal conductivity (OFHC) copper disks is of great interest as copper is widely used material for high power rated mirrors in laser and other optical systems. It is difficult to super finish copper using traditional finishing processes as it is soft and can be scratched easily. Flexible tools that conform to component shape and maintain low as well as uniform pressure are needed for finishing of soft materials. In this work, open-cell porous flexible abrasive tools are developed using solvent casting method with polyurethane as the base polymer and SiC particles as abrasives. The open-cell porous tools are saturated with deionized water before use. The tools are self-replenishing as the abrasives are uniformly dispersed in the tool and the fluid trapped in pores acts as coolant as well as lubricant. The viscoelastic behavior of the fabricated tools with different abrasive concentrations is characterized using a dynamic mechanical analyzer (DMA). Spot finishing experiments are carried out to optimize the tool RPM, tool compression, and abrasive concentration for better surface finish. The average areal surface roughness (Sa) of copper disk reduced to 54 nm from 946 nm.

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Edge finishing of large turbine casings using defined multi-edge and abrasive tools in automated cells

Cited by 21 publications

References 25 publications

Evaluation of Thin Wall Milling Ability Using Disc Cutters

Evaluation of Thin Wall Milling Ability Using Disc Cutters

Process Optimization for Robotic Ultrasonic Strengthening of Aviation Blade Surfaces Based on Intelligent Compliance Control

Finishing of OFHC copper using fluid filled open-cell porous flexible abrasive impregnated tools

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