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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.

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Figures

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Fig. 1

Original feeding path and its corresponding simplified feeding path

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Fig. 2

Electrode discharging part and its containing hexahedron

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Fig. 3

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

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Fig. 4

Contour error between simplified and original paths

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Fig. 5

Flowchart of simplifying a G-code feeding path

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Fig. 6

Steps for simplification of G-codes

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Fig. 7

Check contour error at each discrete point along a simplified path

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Fig. 8

Three-dimensional models of the shrouded blisk and the electrode

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Fig. 9

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

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Fig. 10

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

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Fig. 11

A shrouded blisk machined on the six-axis EDM machine

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Fig. 12

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

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Fig. 13

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

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