Papers by Keyword: Adaptive Machining

Abstract: Blades are important components of aviation-engine, with complex shape and high precision machining. The radius of curvature of the leading and trailing edges of the precision forging blades is small and the curvature changes fast. In this paper, the adaptive machining scheme about the leading/trailing edge of the precision forging blade is proposed. Firstly, the measurement model based on theoretical model of the blade is established. Secondly, according to the measurement model, the measurement path planning is proposed. Thirdly, measurement data processing and registration, then blade model reconstructed to generate the new NC code for machining.

Abstract: In gas turbines and turbo jet engines, high performance materials such as nickel-based alloys are widely used for blades and vanes. In the case of repair, finishing of complex turbine blades made of high performance materials is carried out predominantly manually. The repair process is therefore quite time consuming. And the costs of presently available repair strategies, especially for integrated parts, are high, due to the individual process planning and great amount of manually performed work steps. Moreover, there are severe risks of partial damage during manually conducted repair. All that leads to the fact that economy of scale effects remain widely unused for repair tasks, although the piece number of components to be repaired is increasing significantly. In the future, a persistent automation of the repair process chain should be achieved by developing adaptive robot assisted finishing strategies. The goal of this research is to use the automation potential for repair tasks by developing a technology that enables industrial robots to re-contour turbine blades via force controlled belt grinding.

Abstract: Due to different datum position and inevitable distortion from the linear friction welding process, the nominal CAD model from the design stage is no longer suitable for the use of the final NC machining, and that is the main problem for precisely machining complex blisk. In this paper, an adaptive machining approach based on adaptive process model for high precision manufacturing of blisk is proposed and developed. Comparing the nominal model with the inspection result, adaptive process model is reconstructed to describe workpiece localization, allowance distribution and composite error compensation for NC machining of blisk accurately. Firstly, the transformation matrix for allowance optimization is searched fleetly by genetic algorithm with constraint conditions. Secondly, using the cross-section curve blending and deformation compensation method, adaptive model for shape distortion is constructed to solve the part-to-part variation machining problem and to realize precision machining for complex geometry blisk. Finally, based on the adaptive process model, tool paths used for the last NC machining process can then be adaptively generated to implement the different processes work. Example shows that the adaptive machining technology of blisk is feasible and the result is of high precision and efficiency.

Abstract: Final treatment of fine detail surfaces remains an important problem in modern machine building. As a solution to such a task a super finishing processing is widely used. The proposed system is dedicated to creating an oscillating movement of a detail or tool in super finishing wide scale of processing details - crankshaft, cylinder shaped details. This device can create detail or tool amplitudes equal to a detail surface or tool micro relief pitch. In difference to classical systems, the proposed system is operating on sound frequency and enables one to perform a surface treatment during one cycle.