Improvement in the efficiency of the five-axis machining of aerospace blisks

Abstract

Blisks are not easily machined because of their complex curved surfaces and the high-precision requirements of surface machining. Lightweight alloy materials with superior mechanical properties, such as titanium alloy and stainless steel, are popular material choices for manufacturing turbine blisks. However, these materials are difficult to cut and require advanced machine tools and processing technologies. Because aerospace-grade parts are complex and require precise dimensions and high surface quality, machining these parts by using three-axis machine tools is difficult. Using multi-axis machine tools for the machining of complex parts can cause the achievement of precise dimensions, high quality, and the required surface roughness. In the multi-axis machining of aerospace blisks, tool path planning is considered the most difficult task. In this study, we examined the implementation of five-axis machining technology for the manufacturing of an aerospace blisk. Processing modules from computer-aided manufacturing software (NX10) are used for five-axis tool path generating, and 5-axis machining numerical control code is generated through post-processing calculations. Solid cutting simulation software (VERICUT) is used to verify whether tools exhibited overcut or interference. A sensory tool holder (SPIKE) is used to analyze cutting force during the rough machining of a blisk. The sensory tool holder is also adopted to evaluate the spindle runout and tool holding status. In order to obtain a consistent cutting allowance and surface accuracy, the online measurement system is used to generate a measurement path for semi-finish and finish machining. The real cut is performed with SUS304 and demonstrates the practical application. Through improvements in process planning, the machining time was shortened by 16.5%.

Research on Continuous Machining Strategy for Five-Axis Machine Tool: Five-Axis Linkage to Four-Axis Linkage

“…With the added flexibility of adjusting tool orientation through additional degrees of freedom, five-axis machining can achieve highly efficient machining. For intricate surface components like engine blades and turbine blades, the conventional three-axis surface processing technology often falls short in meeting the specific processing requirements due to their uneven spatial curvature [2]. This is where the significance of five-axis processing comes into play.…”

“…Generally, the research on the five-axis machining trajectory primarily centers around refining the interpolation of the five-axis trajectory while evading potential interference and collisions. In the literature, many algorithms have been developed for tool path generation and tool-gauging avoidance to achieve highly efficient tool path planning without gauges [2,12].…”