Abstract

The blisk has been widely used in modern high performance aero-engines of high thrust-weight ratio. Disc milling process provides a reliable way to improve the efficiency of the blisk milling. The process parameters of disc milling have crucial effects on the milling efficiency and physical property of blisk. In this paper, material removal rate, cutter life and thickness of residual stress layer are regarded as optimization targets the key process parameters such as spindle speed, cutting depth and feed speed are optimized. Based on the grey relational analysis, the multi-objective optimization problem is transformed into a single objective optimization problem. At the same time, the problem of non-symmetry influence of key process parameters on optimization targets can be solved. And the influence weight of material removal rate, cutter life and thickness of residual stress layer on the grey relational grade (GRG) are calculated according to principal component analysis. The second order prediction model of GRA is developed by response surface method. On the basis of verifying the accuracy of the model, the influence mechanism of the process parameters coupling on the gray correlation degree is analyzed the optimal process parameter combination is obtained as spindle speed with 81.92 rpm, cutting depth with 5.88 mm and feed rate with 66.0823 mm/min. The experimental research show that the optimal process parameter combination can effectively improve the material removal rate and cutter life and reduce the thickness of residual stress layer.

Highlights

  • The blisk is a new-style key component of aero-engines, which rotor blade is integrated with the wheel disc

  • The blisk is usually fabricated by titanium alloy or high temperature alloy [4,5]

  • The material removal rate is the volume of metal removed in a form of cutting per unit time

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Summary

Introduction

The blisk is a new-style key component of aero-engines, which rotor blade is integrated with the wheel disc. The blisk has been widely utilized for modern high performance aero-engines. The main processing technology of blisk-tunnel is the Computerized Numerical Control (CNC) milling, such as side milling or insert milling. These methods have low efficiencies, severe tool-wear and high manufacturing costs. A new-type tool namely disc milling cutter is employed to machine aero-engine blisk-tunnels for its higher efficiency and reliability. The process parameters of disc milling have crucial effects on the mechanical performance and physical property of blisk. The workpiece and fixture are changeless for disc milling process the Symmetry 2019, 11, 173; doi:10.3390/sym11020173 www.mdpi.com/journal/symmetry

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