Abstract
To simulate and analyse the real machined parts in virtual environments, virtual machining systems are applied to the production processes. Due to friction, chip forming, and the heat produced in the cutting zone, parts produced using machining operation have residual stress effects. The machining force and machining temperature can cause the deflection error in the machined turbine blades, which should be minimized to increase the accuracy of machined blades. To minimize the residual stress and deflection error of machined parts, optimized machining parameters can be obtained. In the present research work, the application of a virtual machining system is presented to predict and minimize the residual stress and deflection error in a five-axis milling operations of turbine blades. In order to predict the residual stress and deflection error in machined turbine blades, finite element analysis is implemented. Moreover, to minimize the residual stress and deflection error in machined turbine blades, optimized parameters of machining operations are obtained by using a genetic algorithm. To validate the research work, experimentally determining residual stress by using a X-ray diffraction method from the machined turbine blades is compared with the finite element results obtained from the virtual machining system. Also, in order to obtain the deflection error, the machined blades are measured by using the CMM machines. Thus, the accuracy and reliability of machined turbine blades can be increased by analysing and minimizing the residual stress and deflection error in virtual environments.
Highlights
The residual stress in machined parts can be generated as a result of mechanical, thermal, and chemical effects in chip forming of metal cutting operations
The deflection error due to machining forces and cutting temperature is minimized to increase the accuracy of machined turbine blades
To predict and minimize residual stress and deflection error in a five-axis turbine blade milling operations, a virtual machining system is developed in the study
Summary
The residual stress in machined parts can be generated as a result of mechanical, thermal, and chemical effects in chip forming of metal cutting operations. To analyse the influence of the machining parameters, such as cutting speed as well as feed rate, on the surface roughness and residual stresses in produced parts using milling operation, the finite element method is used by Zhang and Wu [10]. The application of a virtual machining system is presented to predict and minimize the residual stress and deflection error in a five-axis milling operations of turbine blades. The cutting forces as well as cutting temperatures for each position of cutting tool along machining paths are calculated in order to obtain residual stress and deflection error of blades due to machining operations by using the finite element analysis (FEA).
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