Skip to main content
SpringerLink
Log in

Precise machining based on Ritz non-uniform allowances for titanium blade fabricated by selective laser melting

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Selective laser melting (SLM) is an increasingly concerned trend in Ti-6Al-4V blade manufacturing, while the SLMed Ti-6Al-4V blade cannot be used directly because of poor surface integrity and high residual stresses. Precise machining after SLM is a feasible solution but also a challenge. The low rigidity of the blade will lead to deformation when machining. The deformation can lead to surface error and may make defect parts. Two-step machining processes to address the problems were proposed in this paper. First, a non-uniform allowances distribution was allocated and optimized in semi-finishing based on Ritz solution to elastic deformation. The blade was simplified as a cantilever thin plate with various thicknesses, and the thicknesses of finishing allowances were designed and optimized on the premise of ensuring the thin-wall stiffness of the blade, so as to realize the design of Ritz non-uniform allowances. Then, finishing machining was conducted to achieve precise parts. A blade deformation model was established to evaluate part distortions with cutting force moving and changing. Finite element analysis (FEA) and experimental validation in ball-end milling of a blade were conducted. FEA results and experimental results showed dimensional errors have been reduced up to 50%. Further surface tests demonstrated that the mean surface roughness reduced from 7.88 to 0.815 μm. And the residual surface stresses of the SLM samples changed after semi-finishing machining due to the residual stresses relaxation and redistribution. The results demonstrated that the proposed method enhanced the surface quality of the blade fabricated by SLM.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15

Similar content being viewed by others

Availability of data and material

Not applicable.

Code availability

Not applicable.

References

  1. Jiménez A, Bidare P, Hassanin H, Tarlochan F, Dimov S, Essa K (2021) Powder-based laser hybrid additive manufacturing of metals: a review. Int J Adv Manuf Technol 114:63–96. https://doi.org/10.1007/s00170-021-06855-4

    Article  Google Scholar 

  2. Gurrappa I (2003) Characterization of titanium alloy Ti-6Al-4V for chemical, marine and industrial applications. Mater Charact 51:131–139. https://doi.org/10.1016/j.matchar.2003.10.006

    Article  Google Scholar 

  3. Li Z, Tuysuz O, Zhu L, Altintas Y (2018) Surface form error prediction in five-axis flank milling of thin-walled parts. Int J Mach Tools Manuf 128:21–32. https://doi.org/10.1016/j.ijmachtools.2018.01.005

    Article  Google Scholar 

  4. Huang N, Bi Q, Wang Y, Sun C (2014) 5-axis adaptive flank milling of flexible thin-walled parts based on the on-machine measurement. Int J Mach Tools Manuf 84:1–8. https://doi.org/10.1016/j.ijmachtools.2014.04.004

    Article  Google Scholar 

  5. Gao Y, Ma J, Jia Z, Wang F, Si L, Song D (2016) Tool path planning and machining deformation compensation in high-speed milling for difficult-to-machine material thin-walled parts with curved surface. Int J Adv Manuf Technol 84:1757–1767. https://doi.org/10.1007/s00170-015-7825-4

    Article  Google Scholar 

  6. Li Z, Zhu L (2019) Compensation of deformation errors in five-axis flank milling of thin-walled parts via tool path optimization. Precis Eng 55:77–87. https://doi.org/10.1016/j.precisioneng.2018.08.010

    Article  Google Scholar 

  7. Song Q, Shi J, Liu Z, Wan Y (2016) Dynamic analysis of rectangular thin plates of arbitrary boundary conditions under moving loads. Int J Mech Sci 117:16–29. https://doi.org/10.1016/j.ijmecsci.2016.08.005

    Article  Google Scholar 

  8. Shi J, Gao J, Song Q, Liu Z, Wan Y (2017) Dynamic deformation of thin-walled plate with variable thickness under moving milling force. Procedia CIRP 58:311–316. https://doi.org/10.1016/j.procir.2017.03.329

    Article  Google Scholar 

  9. Wu K, He N, Liao WH, Zhao W (2004) Study on machining deformations and their control approaches of the thin-web in end milling. China Mechanical Engineering 15(8):670–674

    Google Scholar 

  10. Chen W, Lou P, Chen H (2009) Active compensation methods of machining deformation of thin-walled parts. Hangkong Xuebao/Acta Aeronautica et Astronautica Sinica 30:570–576

    Google Scholar 

  11. Chen YZ, Chen WF, Liang RJ, Feng T (2017) Machining allowance optimal distribution of thin-walled structure based on deformation control. Appl Mech Mater 868:158–165. https://doi.org/10.4028/www.scientific.net/AMM.868.158

    Article  Google Scholar 

  12. Tian W, Ren J, Wang D, Zhang B (2018) Optimization of non-uniform allowance process of thin-walled parts based on eigenvalue sensitivity. Int J Adv Manuf Technol 96:2101–2116. https://doi.org/10.1007/s00170-018-1740-4

    Article  Google Scholar 

  13. Shan C, Zhao Y, Liu W, Zhang D (2013) A nonuniform offset surface rigidity compensation strategy in numerical controlled machining of thin-walled cantilever blades. Hangkong Xuebao/Acta Aeronautica et Astronautica Sinica 34:686–693

    Google Scholar 

  14. Rahman M, Heikkala J, Lappalainen K (2000) Modeling, measurement and error compensation of multi-axis machine tools. Part I: theory. Int J Mach Tools Manuf 40:1535–1546. https://doi.org/10.1016/S0890-6955(99)00101-7

    Article  Google Scholar 

  15. Ratchev S, Liu S, Huang W, Becker AA (2006) An advanced FEA based force induced error compensation strategy in milling. Int J Mach Tools Manuf 46:542–551. https://doi.org/10.1016/j.ijmachtools.2005.06.003

    Article  Google Scholar 

  16. Guo H, Zuo DW, Wu HB, Xu F, Tong GQ (2009) Prediction on milling distortion for aero-multi-frame parts. Mater Sci Eng, A 499:230–233. https://doi.org/10.1016/j.msea.2007.11.137

    Article  Google Scholar 

  17. Zhang J, Lin B, Fei J, Huang T, Xiao J, Zhang X, Ji C (2018) Modeling and experimental validation for surface error caused by axial cutting force in end-milling process. Int J Adv Manuf Technol 99:327–335. https://doi.org/10.1007/s00170-018-2468-x

    Article  Google Scholar 

  18. Khandagale P, Bhakar G, Kartik V, Joshi SS (2018) Modelling time-domain vibratory deflection response of thin-walled cantilever workpieces during flank milling. J Manuf Process 33:278–290. https://doi.org/10.1016/j.jmapro.2018.05.011

    Article  Google Scholar 

  19. Zozulya VV, Cartmell S, Basak TK (2011) Numerical solution of the Kirchhoff plate bending problem with BEM. ISRN Mechanical Engineering 2011:295904. https://doi.org/10.5402/2011/295904

    Article  Google Scholar 

  20. Ritz W (1909) Theorie der Transversalschwingungen einer quadratischen Platte mit freien Rändern. Ann Phys 333:737–786. https://doi.org/10.1002/andp.19093330403

    Article  MATH  Google Scholar 

  21. Sadílek M, Poruba Z, Čepová L, Šajgalík M (2020) Increasing the accuracy of free-form surface multiaxis milling. Materials 14:25. https://doi.org/10.3390/ma14010025

    Article  Google Scholar 

  22. Mirkoohi E, Bocchini P, Liang SY (2019) Inverse analysis of residual stress in orthogonal cutting. J Manuf Process 38:462–471. https://doi.org/10.1016/j.jmapro.2019.01.033

    Article  Google Scholar 

  23. Huang X, Zhang X, Han D (2015) An analytical model of residual stress for flank milling of Ti-6Al-4V. Procedia CIRP 31:287–292. https://doi.org/10.1016/j.procir.2015.03.061

    Article  Google Scholar 

  24. Yao C, Zhang J, Cui MC, Tan L, Shen XH (2020) Machining deformation prediction of large fan blades based on loading uneven residual stress. Int J Adv Manuf Technol 107:4345–4356. https://doi.org/10.1007/s00170-020-05316-8

    Article  Google Scholar 

Download references

Funding

This work was financially supported by the National Natural Science Foundation of China (Nos. 51775280 and 51675285).

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing, 210094, China

    Bo Zhang, Juntang Yuan, Zhenhua Wang & Xi Li

Authors
  1. Bo Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Juntang Yuan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Zhenhua Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Xi Li
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Juntang Yuan or Zhenhua Wang.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

The authors gave consent for publication.

Competing interests

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhang, B., Yuan, J., Wang, Z. et al. Precise machining based on Ritz non-uniform allowances for titanium blade fabricated by selective laser melting. Int J Adv Manuf Technol 119, 6029–6044 (2022). https://doi.org/10.1007/s00170-022-08701-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-08701-7

Keywords

Search

Navigation