Research Papers

Simplification of a G-Code Feeding Path in Roughing Multi-Axis Electrical Discharging Machining for Shrouded Blisks With a Contour Error Constraint

[+] Author and Article Information
Xue-Cheng Xi

State Key Laboratory of Mechanical
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: xixuecheng@gmail.com

Hao Chen

State Key Laboratory of Mechanical
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: billychen8948@hotmail.com

Wan-Sheng Zhao

State Key Laboratory of Mechanical
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: zws@sjtu.edu.cn

1Corresponding author.

Manuscript received September 24, 2016; final manuscript received July 28, 2017; published online September 13, 2017. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 139(11), 111013 (Sep 13, 2017) (9 pages) Paper No: MANU-16-1517; doi: 10.1115/1.4037569 History: Received September 24, 2016; Revised July 28, 2017

Multi-axis electrical discharging machining (EDM) is the main manufacture method for shrouded blisks, which are key components of aero and rocket engines. Involving both linear and rotational axes, a feeding path for machining a narrow and twisted channel consists of a large number of G-code lines. Accelerations and decelerations at junctions, which connect two neighboring G-code lines, can significantly reduce the machining efficiency. In this paper, a new simplification of feeding paths in roughing EDM for shrouded blisks is proposed in order to reduce the number of junctions on a feeding path. However, deviating from the original feeding path, a simplified feeding path can bring over contour errors which can cause geometrical errors of workpieces. Contour error can thus serve as a criterion for simplifying the original path. Eight vertices of a hexahedron, which contains the electrode, are used to represent all points inside and on an electrode. Forward kinematics of a six-axis EDM machine is used to calculate the contour errors of the eight vertices when the electrode feeds along a simplified path. A simplified feeding path can be found provided that the contour error constraint is respected. Machining tests show that the use of a simplified feeding path in roughing EDM machining can reduce the average total machining time by 26.5% without significant impact on surface roughness and white layer thickness.

Copyright © 2017 by ASME
Your Session has timed out. Please sign back in to continue.


Harada, H. , 1985, “ Performance Characteristics of Shrouded and Unshrouded Impellers of a Centrifugal Compressor,” ASME J. Eng. Gas Turbines Power, 107(2), pp. 528–533. [CrossRef]
Yoon, S. , Curtis, E. , Denton, J. , and Longley, J. , 2013, “ The Effect of Clearance on Shrouded and Unshrouded Turbines at Two Levels of Reaction,” ASME J. Turbomach., 136(2), p. 021013. [CrossRef]
Jing, J. , Zhao, H. , Liu, Y. , Li, X. , and Liu, Z. , 2011, “ Tool Path Planning in Finish-Milling Process for Integrally-Shrouded Impeller Channels With Rings,” International Conference on Electronic and Mechanical Engineering and Information Technology (EMEIT), Harbin, China, Aug. 12–14, pp. 1635–1638.
Chen, K.-H. , 2011, “ Investigation of Tool Orientation for Milling Blade of Impeller in Five-Axis Machining,” Int. J. Adv. Manuf. Technol., 52(1–4), pp. 235–244. [CrossRef]
Zhan, H.-J. , Zhao, W.-S. , and Wang, G. , 2000, “ Manufacturing Turbine Blisks,” Aircr. Eng. Aerosp. Technol., 72(3), pp. 247–252. [CrossRef]
Li, G. , Zhao, W.-S. , Wang, Z.-L. , and Wu, X. , 2007, “ A Special Cad/Cam Software for Electro-Discharge Machining of Shrouded Turbine Blisks,” J. Shanghai Univ. (English Ed.), 11(1), pp. 74–78. [CrossRef]
Liu, X. , Kang, X. , Xi, X. , Liang, W. , and Zhao, W. , 2013, “ Electrode Feed Path Planning for Multi-Axis EDM of Integral Shrouded Impeller,” Int. J. Adv. Manuf. Technol., 68(5–8), pp. 1697–1706. [CrossRef]
Fujiki, M. , Ni, J. , and Shih, A. J. , 2011, “ Tool Path Planning for Near-Dry EDM Milling With Lead Angle on Curved Surfaces,” ASME J. Manuf. Sci. Eng., 133(5), p. 051005. [CrossRef]
Kunieda, M. , Lauwers, B. , Rajurkar, K. P. , and Schumacher, B. M. , 2005, “ Advancing EDM Through Fundamental Insight Into the Process,” CIRP Annals Manuf. Technol., 54(2), pp. 64–87. https://nebraska.pure.elsevier.com/en/publications/advancing-edm-through-fundamental-insight-into-the-process
Cetin, S. , Okada, A. , and Uno, Y. , 2003, “ Electrode Jump Motion in Linear Motor Equipped Die-Sinking EDM,” ASME J. Manuf. Sci. Eng., 125(4), pp. 809–815. [CrossRef]
Fan, W. , Lee, C.-H. , and Chen, J.-H. , 2015, “ A Realtime Curvature-Smooth Interpolation Scheme and Motion Planning for CNC Machining of Short Line Segments,” Int. J. Mach. Tools Manuf., 96, pp. 27–46. [CrossRef]
Huo, F. , and Poo, A.-N. , 2013, “ Precision Contouring Control of Machine Tools,” Int. J. Adv. Manuf. Technol., 64(1–4), pp. 319–333. [CrossRef]
Xi, X.-C. , Poo, A.-N. , and Hong, G.-S. , 2009, “ Improving Contouring Accuracy by Tuning Gains for a Bi-Axial CNC Machine,” Int. J. Mach. Tools Manuf., 49(5), pp. 395–406. [CrossRef]
Ramesh, R. , Mannan, M. A. , and Poo, A. N. , 2000, “ Error Compensation in Machine Tools—A Review—Part I: Geometric, Cutting-Force Induced and Fixture-Dependent Errors,” Int. J. Mach. Tools Manuf., 40(9), pp. 1235–1256. [CrossRef]
Ramesh, R. , Mannan, M. A. , and Poo, A. N. , 2000, “ Error Compensation in Machine Tools—A Review—Part II: Thermal Errors,” Int. J. Mach. Tools Manuf., 40(9), pp. 1257–1284. [CrossRef]
Dong, J. , Wang, T. , Li, B. , and Ding, Y. , 2014, “ Smooth Feedrate Planning for Continuous Short Line Tool Path With Contour Error Constraint,” Int. J. Mach. Tools Manuf., 76, pp. 1–12. [CrossRef]
Sun, Y. , Zhao, Y. , Bao, Y. , and Guo, D. , 2015, “ A Smooth Curve Evolution Approach to the Feedrate Planning on Five-Axis Toolpath With Geometric and Kinematic Constraints,” Int. J Mach. Tools Manuf., 97, pp. 86–97. [CrossRef]
Zhu, L. , Zhao, H. , and Ding, H. , 2013, “ Real-Time Contouring Error Estimation for Multi-Axis Motion Systems Using the Second-Order Approximation,” Int. J. Mach. Tools Manuf., 68, pp. 75–80. [CrossRef]
Sencer, B. , Altintas, Y. , and Croft, E. , 2009, “ Modeling and Control of Contouring Errors for Five-Axis Machine Tools—Part I: Modeling,” ASME J. Manuf. Sci. Eng., 131(3), p. 031006. [CrossRef]
Murray, R. M. , Li, Z. , Sastry, S. S. , and Sastry, S. S. , 1994, A Mathematical Introduction to Robotic Manipulation, CRC Press, Boca Raton, FL.


Grahic Jump Location
Fig. 1

Original feeding path and its corresponding simplified feeding path

Grahic Jump Location
Fig. 2

Electrode discharging part and its containing hexahedron

Grahic Jump Location
Fig. 3

Hexahedron along original path on the left and simplified path on the right

Grahic Jump Location
Fig. 4

Contour error between simplified and original paths

Grahic Jump Location
Fig. 5

Flowchart of simplifying a G-code feeding path

Grahic Jump Location
Fig. 6

Steps for simplification of G-codes

Grahic Jump Location
Fig. 7

Check contour error at each discrete point along a simplified path

Grahic Jump Location
Fig. 8

Three-dimensional models of the shrouded blisk and the electrode

Grahic Jump Location
Fig. 9

Number of G-code lines after simplification versus maximum contour error

Grahic Jump Location
Fig. 10

Comparison between original path and simplified path when εmax = 0.1 mm

Grahic Jump Location
Fig. 11

A shrouded blisk machined on the six-axis EDM machine

Grahic Jump Location
Fig. 12

Comparative machining tests: channels 1, 2, 3 machined by the simplified path, and channels 4, 5, 6 machined by the original path

Grahic Jump Location
Fig. 13

White layer thickness: (1) 5.89 μm for original path; (2) 6.51 μm for simplified path




Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In