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Layout optimization of auxiliary support for deflection errors suppression in end milling of flexible blade

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Abstract

The service performance and life of the aero-engine are directly affected by the blade machining accuracy. In the end milling of the flexible blade, the profile tolerance would usually be violated by the deflection errors induced by excessive static deformations under the action of milling force. In order to predict the blade deflection errors, this paper presents an iterative algorithm considering the coupling relationship between milling force and elastic deformation based on the milling finite element simulation model. Then a novel multipoint rod-shaped auxiliary support technology is proposed to suppress the blade deflection errors. Taking the influence of layout parameters on blade deflection errors into account, the layout of auxiliary support is optimized by a genetic algorithm. To verify the effectiveness of the proposed method, an auxiliary support mechanism is designed and manufactured, and the deflection errors suppression experiment is implemented. The measured results show that the prediction error of blade maximum deflection is 17.6%. Furthermore, the blade average deflection error on two measured curves reduces from 45.88 μm to 24.39 μm with the support of the designed mechanism. Thus, this auxiliary support mechanism and layout optimization method can achieve higher accuracy in blade milling.

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Funding

This research was supported by the National Key R&D Program of China (No. 2020YFB1710400), the Natural Science Basic Research Program of Shaanxi (No. 2020JQ-183), and the Fundamental Research Funds for the Central Universities under Grant (No. 31020190502007).

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Authors and Affiliations

  1. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine (Northwestern Polytechnical University), Ministry of Education, Xi’an, 710072, China

    Baohai Wu, Zhiyang Zheng, Jiao Wang, Zhao Zhang & Ying Zhang

  2. Key Laboratory of High Performance Manufacturing for Aero Engine (Northwestern Polytechnical University), Ministry of Industry and Information Technology, Xi’an, 710072, China

    Baohai Wu, Zhiyang Zheng, Jiao Wang, Zhao Zhang & Ying Zhang

Authors
  1. Baohai Wu
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  2. Zhiyang Zheng
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  3. Jiao Wang
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  4. Zhao Zhang
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  5. Ying Zhang
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Contributions

Baohai Wu: supervision, conceptualization, methodology, resources, and funding acquisition. Zhiyang Zheng: methodology, experimentation, data curation, and writing original draft. Jiao Wang: supervision and methodology. Zhao Zhang: supervision, reviewing and editing. Ying Zhang: supervision, reviewing and editing. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Zhao Zhang.

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Wu, B., Zheng, Z., Wang, J. et al. Layout optimization of auxiliary support for deflection errors suppression in end milling of flexible blade. Int J Adv Manuf Technol 115, 1889–1905 (2021). https://doi.org/10.1007/s00170-021-07174-4

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  • DOI: https://doi.org/10.1007/s00170-021-07174-4

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