A new localization theory of adaptive machining of near-net-shape blades

Abstract

In the fabrication of aero-engine blades, a great deal is gained when massive material removal is avoided at the end of the process, and as little as possible material is left on the blade billet. Due to the uncertainty of pre-process, the billet shapes are inconsistent. Sometimes, the near-net-shape billet doesn’t cover the blade design surface to be cut. Therefore, blade localization is necessary for these billets before the machining. In conventional localization methods, the design surface’s location focused on guaranteeing enough material to be cut. However, because the to-be-cut surface is in near-net and free-form shape, it is difficult to find a valid localized surface model to generate the tool path. Different from the localized surface is taken as rigid in previous investigation, it is allowed to deviate from the design surface no more than the tolerance band. In term of this principle, the tolerance band is utilized to promote localization ability. A series of optimization models with different priorities is established to avoid the abandonment expensive blade billet. Finally, with the experiments performed on the near-net-shape blades, the blade localization theory and the promotion of localization ability are verified.