Papers by Keyword: Blisk

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Authors: Jun Ji, Ding Hua Zhang, Shan Li, Bing Chen
Abstract: Multidisciplinary design and simulation is a very effective process to balance the different discipline design requirements and gain the optimal design result. The paper proposes a master model approach in order to maintain the model associativity and consistency in multidisciplinary design and simulation for compressor blisk. The research presents a master model-centered model structure, which is composed of master model, context model and application model. In the proposed master model-based multidisciplinary design and simulation process, master model is the kernel model and shared by each discipline. In addition, there is an associative relationship among these models. Then, the paper studies the modeling method for the master model of blisk and the model mapping and associativity maintaining method for multidisciplinary design and simulation. A series of computation results demonstrate the performance of the proposed approach.
Authors: Yan Hui Yang, Dong Liu, Guo Jie Gao, Jian Guo Wang
Abstract: Isothermal compression tests were conducted at various temperature and strain rate combinations over the hot working range (880 to 1040°C and 0.01 to 10.0 s-1) of TC11 alloy. Based on the experimental data, the strain rate sensitivity factors m were calculated. Both the efficiency of power dissipation and the instability parameter were computed, and then processing maps incorporated instability maps were accordingly established at strains of 0.1, 0.3 and 0.6. A method to optimize the forging process of Titanium alloy blisk was proposed based on the processing map. The optimized process of TC11 alloy blisk was achieved using the proposed method and was verified by numerical simulation and experiment. The results showed that this optimal process is applicable to produce blisk with duplex structures.
Authors: Yao Nan Cheng, Yue Zhang, Dian Ge Zuo, Xin Min Feng
Abstract: Blisks are important components of aircraft engines. Its machining plays an important role in a aerospace industry. Blisk processing efficiency has become a hot topic in the field of machining. Disk milling is a new processing method to achieve efficiency. In order to optimize disk milling process parameters of blisk, the use of full-factor experimental for researching TC4 titanium disc milling process. Analyze the impact of different cutting parameters on cutting force, the results show: during milling titanium by Discal Cutter, with the increasing of feed per tooth, the cutting force increases. But cutting forces in three directions has the different influence. Feed per tooth corresponding with radial cutting depth. In order to guarantee the material removal rate, it can be selected smaller feed per tooth and larger radial cutting depth. Through the stress simulation analysis on the blade, it can be carried out that the maximum strain of blade is concentrated at the tip arc. The equivalent stress is mainly concentrated at the main cutting edge and the tip arc. It can provide the basis for future tool design.
Authors: Peng Bing Zhao, Yao Yao Shi
Abstract: According to the problems of low efficiency and high cost in blisk manufacturing, based on large margin slotting and rough machining, a kind of compound and efficient powerful milling process was proposed, that is, disc milling-plunge milling-flank milling. In order to compare the effect of this new process and the traditional plunge milling or flank milling, experiment on disc milling and plunge milling processing performance was carried out. Compared with plunge milling, the cutting force and tool vibration of disc milling are larger, but its processing efficiency was improved significantly. The experiment proved that the compound and efficient powerful milling process is feasible and effective for the large margin slotting and rough machining of blisk.
Authors: Tian Li, Wu Yi Chen, Ru Feng Xu, Dan Wang
Abstract: To satisfy the requirement in blisk machining, a barrel-ball milling (BBM) cutter suitable for machining both blade and hub is presented in this paper. The selection of cutter parameter and calculation of cutter location were put forward. The new efficient machining cutter location via the advanced optimization on cutter machining strip width was gained. By the numerical simulation of blisk blade machining, the feasibility of the BBM cutter and cutter location strategy were verified. The result showed that the efficiency of this method was increased to more than three times compared to the machining with a ball cutter.
Authors: Ji Hao Duan, Yao Yao Shi, Xiao Jun Lin, Ting Dong
Abstract: The blade and blisk manufacturing includes polishing process when the surface roughness and size requirement of profile are disqualified after milling process. This polishing process is mainly carried out manually by skilled workers or NC machines. However, the existing polishing technology always leads to surface quality instability and inconsistency because of the complex free-form surface of blade and blisk. Therefore, in this paper, based on the research of polishing requirements and methods of blade and blisk, an automatic 6-axis polishing machine was proposed in order to enhance surface quality. And then, a polishing mechanism was designed using flexible technique to make the polishing tool accommodate surface waviness which was produced in milling process. In addition, the working principle and control method of flexible polishing mechanism were studied. Finally, the polishing test results of blade and blisk showed that the profile error was about 0.06mm and the surface roughness was less than Ra0.4 after automatic polishing. Compared with the manual polishing process, the automatic polishing technology not only increased the polishing efficiency and quality stability, but also reduced labor intensity largely.
Authors: Rana Noman Mubarak, Jen Yuan Chang
Abstract: Effects on structure designs on free vibrations of integrated bladed rotor (IBR) have been conducted in this research through finite element simulations. Migration of natural frequencies is characterized through parameter studies considering changes of blade angle and blade thickness on an underlying uniform axis-symmetric rotor. Recurring coupled repeated doublet modes, defined as replica modes, has been observed in this study by characterizing blade’s vibrations in-phase or out-of-phase to disk’s vibrations. Veering and cluster of replica modes’ natural frequencies are observed with respect to the blade design parameters. Fourier content for low frequency replica component is found to be sensitive and tunable to blade angle design, which has implications on forced response of spinning IBR in engineering applications.
Authors: Guang Xia Chen, Jian Fu Hou
Abstract: Abstract. The objective of this paper is to probabilistically evaluate the effects of mistuned sectors on the dynamic characteristics of an integrally bladed disk (blisk). Small blade to blade physical variation in a disk is termed as mistuning. In this study, the dynamic characteristics of the perfectly tuned blisk were firstly analysed as a baseline. Secondly, a probabilistic approach is used for the mistuning analysis of a blisk. A reduced-order method named as the subset of nominal modes (SNM) was used to generate modes for a mistuned blisk from a cyclic perfectly tuned FE model without creating the full model. Furthermore, as only the modes with natural frequencies close to the modes of interest were considered, a relatively shorter computational time and a much smaller model size than a full blisk model is used. Therefore, the dynamic characteristics of the forced response for random mistuned blisks were obtained.
Authors: Lei Zhang, Qiang Yuan, Qing Zhou Sun, Yu Song, Ji Zhao
Abstract: The blisk is an important component of aviation engine and its level of machining and measurement will directly affect the application properties of the engine. This paper investigates the on-line measurement of single blade of the blisk. The section lines and the points to be measured are determined by using the empirical formula based on B-spline theory and feature point extraction algorithm. The probe-blade interference problem is solved by dividing the measurement area into different sectors and the posture angle of the probe in different inference-free sector domain is determined. The CATIA simulation is conducted to validate the correctness of the path planning algorithm for measurement. The measuring path planning plays an important role in improving the efficiency and reducing the cost of measurement.
Authors: Chuang Guo Hu, Ding Hua Zhang, Jun Xue Ren, Lei Yang
Abstract: The study presents a new method for 5-axis machining of blisk, which consists of both roughing tunnels and finishing blades. The ruled surface is used to approximate the freeform surface of blade, and the boundary contour of the tunnel is then determined. Based on the double point offset method, the 5-axis tool paths for roughing blisk tunnel region are generated. Similarly, by linking the corresponding points on the tool center curves and the tool axis drive curves, the spiral tool paths are developed to finish milling thin-walled blades taking into account the residual stresses induced part distortion during machining. This strategy is experimentally verified.
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