Abstract
Removing excess material from build-up welding by milling is a critical step in the repair of blades from aircraft engines. This so-called recontouring is a very challenging machining task. Shape deviations often result from the deflection of tool and workpiece due to process forces. Considering the individuality of repair cases, compensation of those deflections by process force measurement and online tool path adaption is a very suitable method. However, there is one caveat to this reactive approach. Due to causality, a corrective movement, following a force variation, is always delayed by a finite reaction time. At this moment, though, the displacement has already manifested itself as a deviation in the machined surface. To overcome those limitations and to improve compensation beyond the reduction of control delays, this study proposes a novel approach of anticipatory online compensation. Flank-milling experiments with abrupt changes in the tool-workpiece engagement conditions are conducted to investigate the limitations of reactive compensation and to explore the potential of the new anticipatory approach.
Highlights
Removing excess material from build-up welding by milling is a critical step in the repair of blades from aircraft engines
The repair procedure for engine blades usually consists of four basic steps that can be carried out using different technologies
This study investigates the limitations of reactive deflection compensation in milling processes with dynamically changing contact conditions
Summary
Removing excess material from build-up welding by milling is a critical step in the repair of blades from aircraft engines. This so-called recontouring is a very challenging machining task. A corrective movement, following a force variation, is always delayed by a finite reaction time At this moment, though, the displacement has already manifested itself as a deviation in the machined surface. Excess material is removed in the recontouring process, for example, by manually guided milling or belt grinding. This determines the final shape and surface topography of the blade. In order to ensure consistent data management along the process chain and, in particular, to guarantee the exchange of data between the manufacturing and simulation environments, a virtual workpiece twin was developed that carries all the workpiece-related data [5]
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