Abstract
The precision forming process is currently used for many difficult-to-cut parts such as aero-engine blades. However, satisfying the tolerance requirement of the forming accuracy is difficult. Thus, precision machining is used to ensure final accuracy of the part. The error of the near-net shape caused by the thermal process cannot be ignored in the machining process. If the cutting tool path is generated in terms of the design blade model, it would be too difficult to satisfy the material allowance and tolerance requirement of the design blade. In this paper, we propose a new flexible localization method to reconstruct a to-be-cut surface which improves the qualification rate. In this method, the tolerance and material allowance requirements are transformed into optimization constraints. Furthermore, the profile curves of the to-be-reconstructed blade surface are converted into the optimization variables. The material allowance distribution of the to-be-reconstructed surface needs to be as uniform as possible. Through this optimization, the profile curves of the blade surface at the specified height are obtained and used to evaluate the to-be-cut blade model. Finally, a typical compressor blade model is used to verify the proposed method. The results show that the approach can meet the tolerance requirements and ensure sufficient material allowance for the near-net shape blades.
Highlights
Blades are important parts in aerospace production, and determine performance.Regardless of the processing method used to fabricate the blade, it is essential to ensure that the section profiles of the manufactured blade are within the specified profile tolerance
The blade localization before the finish machining is essentially an optimization. The input of this optimization is a set of profile curves ci(v) of the nominal surface, the measured points pi of the blade billet, and the segmented profile tolerance requirements
Our results indicate that the unconstrained optimization is suitable for whole-part localization under large material allowance conditions, such as a casting and forging
Summary
Blades are important parts in aerospace production, and determine performance. Regardless of the processing method used to fabricate the blade, it is essential to ensure that the section profiles of the manufactured blade are within the specified profile tolerance. The measured result representing the blade billet shape is introduced into localization optimization. Astanin et al [12] proposed a workpiece localization optimization algorithm for a free-form surface and a mathematical model was established to ensure that the workpiece had sufficient machining allowance. It is desirable to find a localization method to obtain an optimal to-be-cut blade surface. This surface is used to generate the toolpath that satisfies the material allowance and tolerance requirements. The tOop-tbimei-zcautitonbOlabdjeectsivuer: fTahceeobsjehctoivuelodf thbeeucniofomrmptloe-btee-lcyutcmoavteerriael dis sbuybsttihtuetedblade b sbeynttheeddbistyance between the measured points of the blade billet and the to-be-cut blade surface
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