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research-article

A New, Efficient Process for Rough-Machining Blisks with Multiple Largest Tools Cutting in Patch-by-Patch Strategy

[+] Author and Article Information
Zhiyong Chang

Department of Mechanical Engineering Northwestern Polytechnical University Xi‖an, Shaanxi, China, 710072
changzy@nwpu.edu.cn

Jinan Wen

Department of Mechanical Engineering Northwestern Polytechnical University Xi‖an, Shaanxi, China, 710072
36laosan@mail.nwpu.edu.cn

Zezhong C. Chen

Department of Mechanical Engineering Northwestern Polytechnical University Xi‖an, Shaanxi, China, 710072
zcchen@encs.Concordia.CA

Dinghua Zhang

Department of Mechanical Engineering Northwestern Polytechnical University Xi‖an, Shaanxi, China, 710072Department of Mechanical and Industrial Engineering Concordia University Montreal, Quebec, H3G 1M8 Canada
dhzhang@nwpu.edu.cn

1Corresponding author.

ASME doi:10.1115/1.4036834 History: Received January 08, 2017; Revised May 11, 2017

Abstract

As an important part of gas turbine engines, a blisk (or axial compressor) is complex in shape for its aerodynamic function. Specifically, the pressure and suction surfaces of the blisk blades are designed with free-form surfaces, and the space (or the channel) between two adjacent blades is curved and its width varies significantly. Thus, some blade patches can be machined with large-diameter cutters, and some patches have to be cut with small-diameter cutters. In machining, a best practice is to adopt largest obtainable cutters to cut workpieces for high machining efficiency, better part surface quality and longer tool life. However, it is quite difficult to automatically determine the largest obtainable diameters of the theoretical cutters and plan their paths for 4-axis blade machining. Conventionally, NC programming engineers often employ small-diameter cutters and plan their paths to cut the blades layer by layer in 4-axis milling. Unfortunately, this machining efficiency is low and the cutters wear out quickly. In this research, a new process of rough-machining blisks with multiple largest obtainable tools cutting in patch-by-patch strategy is proposed. Theoretically, an optimization model of the largest allowable diameter of the theoretical cutter at a cutter contact point is established, and an efficient and reliable solver is proposed. Since the cutters are used as large as possible, the machining parameters can be greater and the tool path length is shorter. Therefore, this new process is more efficient than the current method of blisk machining.

Copyright (c) 2017 by ASME
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