Wire-EDM: a potential manufacturing process for gamma titanium aluminides in future aero engines

Khanna

et al. 2019

IJMMM

In the present research, Ti-6Al-4V alloy was processed on wire-cut electrical discharge machine (WEDM) and the machining responses were analysed. The effect of machining variables was investigated on cutting speed (CS) and surface roughness (SR). Taguchi technique-based L 9 orthogonal array was considered for the planning of experiments. Grey relational theory is used for multi-characteristics optimisation. During the research, it was observed that the best optimal setting for the process parameters is A 1 B 2 C 2. At the suggested optimal setting, the predicted value of CS was 0.2044 mm/min and SR was 2.162 μm. These values are predicted at 95% confidence level. Scanning electron microscopy (SEM) investigates the surface morphology after the WEDM process. The surface integrity reveals the white-layer, sub-surface cracks and micro-cracks on the machined surface. The crack intensity increases with the increase of discharge energy.

Section: Introductionmentioning

confidence: 99%

Multi-quality characteristics optimisation on WEDM for Ti-6Al-4V using Taguchi-grey relational theory

Khanna

et al. 2019

IJMMM

Advances in Mechanical Engineering

“…The validation and changeover times of broaching process is relatively long and the process flexibility is poor. 33,35 In the early stage of slot broaching, it is necessary to prepare more than a dozen or even dozens of broaching tools according to the size of slots to complete rough, semi-fine, and fine broaching respectively, and the broaching edge geometry and parameters need to be optimized according to the broaching experiment results. So, the design and verification time of broaching tool may be very long.…”

Section: Broachingmentioning

confidence: 99%

A brief review on the status of machining technology of fir-tree slots on aero-engine turbine disk

Wenshuo

et al. 2022

The machining precision and its consistency of turbine disk fir-tree slots have a direct influence on the performance of aero-engine rotor components. However, the structural dimensions of fir-tree slot are small, and the cutting performance of materials is extremely poor, which lead to great difficulty in machining and very few available machining methods. With the application of new materials in the aero-engines, the machining precision and quality requirements of fir-tree slots are further improved. Therefore, many research achievements on the high-efficiency, high-quality and low-cost machining technology of turbine disk fir-tree slots have been obtained. By summarizing and classifying the machining methods of aero-engine turbine disk fir-tree slots, a brief review on the characteristics of different methods are presented in detail, which provide a reference for selecting the appropriate machining method of turbine disk fir-tree slots in the field of aviation manufacturing. Meanwhile, combined with the research and application status of machining technology of turbine disk fir-tree slots, it is presented that multi-process compound machining is an effective method to realize high-efficiency, high-quality and low-cost precision machining of turbine disk fir-tree slots, such as wire electro discharge machining (wire-EDM) and profiled grinding, wire electrochemical machining (wire-ECM) and profiled grinding, wire-EDM and broaching, milling and broaching.

“…These components are characterized by their ability to withstand extremely high temperatures and pressures during their service life. Advanced materials such as nickel-based alloys and other super-alloys [3] are used to manufacture these parts. Several authors report on the low machinability of these alloys [3,4].…”

Section: Introductionmentioning

confidence: 99%

“…Advanced materials such as nickel-based alloys and other super-alloys [3] are used to manufacture these parts. Several authors report on the low machinability of these alloys [3,4]. Moreover, very complex geometries, extremely good surface finish, and very tight tolerances are very common specifications in components such as the nozzle guide vane (NGV), the so-called blisks (blade integrated disks), or the disc turbine (fir-tree geometry slots).…”

Section: Introductionmentioning

confidence: 99%

Unsupervised Machine Learning for Advanced Tolerance Monitoring of Wire Electrical Discharge Machining of Disc Turbine Fir-Tree Slots

Wang

Sánchez

Ayesta

et al. 2018

Sensors

Manufacturing more efficient low pressure turbines has become a topic of primary importance for aerospace companies. Specifically, wire electrical discharge machining of disc turbine fir-tree slots has attracted increasing interest in recent years. However, important issues must be still addressed for optimum application of the WEDM process for fir-tree slot production. The current work presents a novel approach for tolerance monitoring based on unsupervised machine learning methods using distribution of ionization time as a variable. The need for time-consuming experiments to set-up threshold values of the monitoring signal is avoided by using K-means and hierarchical clustering. The developments have been tested in the WEDM of a generic fir-tree slot under industrial conditions. Results show that 100% of the zones classified into Clusters 1 and 2 are related to short-circuit situations. Further, 100% of the zones classified in Clusters 3 and 5 lie within the tolerance band of ±15 μm. Finally, the 9 regions classified in Cluster 4 correspond to situations in which the wire is moving too far away from the part surface. These results are strongly in accord with tolerance distribution as measured by a coordinate measuring machine.