Parametric design and surface topography analysis of turbine blade processing by turn-milling based on CAM

Ning, Jinsheng; Zhu, Lida

doi:10.1007/s00170-019-04037-x

Cited by 12 publications

(3 citation statements)

References 29 publications

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“…Although five-axis machining is a developed technology, its high cost in terms of machine tools and manpower impairs its application in small and medium-sized enterprises. Consequently, a number of alternative approaches have been proposed in order to get the blades machined on three-or four-axis machines, including the spiral milling on a regular three-axis CNC machine combined with an automatic indexing rotary table [4], the turn-milling on a four-axis machine [5], and the whirling milling process with a disc-mill cutter on a thread-whirling machine [6].…”

Section: Introductionmentioning

confidence: 99%

Elastic Deformation Analysis of the Blade Workpiece in the Milling Process with a Disk-Shaped Cutter

Liu,

Feng

2023

Advances in Transdisciplinary Engineering

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Turbine blades play a decisive role in the performance of turbomachinery. The whirling milling process may provide a cost-effective way to produce blade surfaces. However, due to the low stiffness of blades, elastic deformation of the workpiece is often induced by the cutting force during the blade whirling process. In this paper, the elastic deformation in finish machining blades using a disk-shaped milling cutter on a 3-axis (C/Z/X) CNC machine is investigated. First, the process of the blade-whirling is briefly introduced. Then, the simulation model is established for analysis of the elastic deformation of the workpiece. Seven sections are made along the blade and twenty reference points are set in each section. By applying forces to these points, the deformations at the different location of the blade surface are analysed by means of simulation using the ABAQUS software. The deformation trend and the maximum displacements of the workpiece are identified, which is of great significance for improving the manufacturing quality and efficiency.

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Section: Introductionmentioning

confidence: 99%

Elastic Deformation Analysis of the Blade Workpiece in the Milling Process with a Disk-Shaped Cutter

Liu,

Feng

2023

Advances in Transdisciplinary Engineering

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“…Milling processing technology is closely related to our lives. As shown in figures 1(a), (b), the processing personnel improve the surface quality of the impeller by optimizing the milling process parameters, and use this method to improve the working performance and service life of the aero engine [1]. Figures 1(c), (d) is a large-scale automobile stamping die.…”

Section: Introductionmentioning

confidence: 99%

A roughness calculation method based on milling topography simulation

Zhang¹,

Zheng²,

Zhang³

et al. 2022

Surf. Topogr.: Metrol. Prop.

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The surface texture and roughness parameters of the workpiece after milling have a greater impact on the performance of the workpiece, so the analysis of the milling topography is particularly important. Firstly, the edge line of the ball end milling cutter was modeled. According to the movement law of the milling process, a complete set of milling topography simulation model was established, and a new influencing factor phase difference is proposed. In addition to the conventional cutting parameters, the model also considers the phase difference and tool inclination. Secondly, through the topography analysis and the calculation of the height of the convex peak Hmax, the comparison with the experiment was carried out to further verify the accuracy of the model. Finally, the point cloud data obtained from the topography simulation is processed, the roughness Sa is calculated according to the least square method. and the influence of the phase difference Δφ and the tool inclination β on the milling topography, surface texture and roughness Sa are respectively analyzed. The conclusions obtained provide guidance and reference for industrial parts designers who have specific texture requirements.

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“…In the aerospace industry, five-axis end milling is widely used in the machining of complex structural and surface parts such as aero-engine impellers, blisks, and blades, to avoid the interference between cutters and workpieces. In the abovementioned processing, such as the turning and milling of aero-engine blades [1] and the machining of aero-engine blisks with cycloidal trajectories [2], the tool path curvature and torsion, and cutter-orientation change often appear, which could be a considerable influence on the cutting force [3,4]. Taking the milling of an aero-engine blade in Fig.…”

Section: Introductionmentioning

confidence: 99%

Cutting force prediction considering tool path curvature and torsion based on screw theory

Zhu

Yan

et al. 2021

Int J Adv Manuf Technol

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There are common features such as the tool path curvature and torsion, and cutter-orientation change in sculptured surface machining, which bring new challenges to the accurate prediction of cutting force. Aiming at the tool path curvature and torsion, and cutter-orientation change, a cutting force prediction method based on the screw theory is proposed in this paper. For the first time, the screw theory is used to describe the cutter spatial motion, which includes the feed motion considering the tool path curvature and torsion, and cutter-orientation change. Combining with Frenet frame, the analytical formula of the screw of cutting edge elements is derived through the homogeneous coordinate transformation. Then, the instantaneous uncut chip thickness (IUCT) of each cutting edge element is calculated by the vector projection method. And the cutting state of the cutting edge element is determined by its IUCT and position relative to the workpiece surface, which is updated by the cutter envelope surface along the machined tool path derived with the screw. To verify the effectiveness of the proposed cutting force prediction method, a milling experiment is conducted on a conical surface workpiece along a tool path with curvature and torsion characteristics, and changing cutter-orientations. Then, the effects of the tool path curvature and torsion, and cutter-orientation change on the cutting force are simulated and analyzed. The results show that the proposed cutting force model based on the screw theory has higher prediction accuracy for the sculpture surface machining with curving and torsional tool paths and changing cutter-orientations.

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Parametric design and surface topography analysis of turbine blade processing by turn-milling based on CAM

Cited by 12 publications

References 29 publications

Elastic Deformation Analysis of the Blade Workpiece in the Milling Process with a Disk-Shaped Cutter

Elastic Deformation Analysis of the Blade Workpiece in the Milling Process with a Disk-Shaped Cutter

A roughness calculation method based on milling topography simulation

Cutting force prediction considering tool path curvature and torsion based on screw theory

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