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Solid subtraction model for the surface topography prediction in flank milling of thin-walled integral blade rotors (IBRs)

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Abstract

Current CAM and milling verification software packages are not ready to predict form and surface errors derived from non-ideal conditions such as runout tool error or tool–workpiece flexibility. As a consequence, high-end parts like integral blade rotors (IBR) suffer from this lack of estimation to achieve a sound manufacturing process preparation. This work describes the implementation of a cutting force prediction model that introduces the radial engagement reduction caused by (i) tool runout and (ii) workpiece flexibility. The model is used as the seed for a calculation module based on solid modeling to obtain the surface roughness and topography applying the cutting force–wall restitution equilibrium, making use of the power of CAM solid modelers for the final topography definition. This idea takes advantage of the good accuracy of current solid modelers in comparison with the z-map topographical approach for obtaining the cutter–workpiece engagement (CWE) at each tool path step. Several flank milling tests were carried out to validate the simulations. The results demonstrated a significant level of accuracy to predict shape errors. The model may be integrated in a CAM procedure, and it is a useful utility for reducing deformation on the manufacturing of blisks and impellers.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of the Basque Country UPV/EHU, Vitoria-Gasteiz, Spain

    E. Artetxe, Dv. Olvera, L. N. López de Lacalle, F. J. Campa & A. Lamikiz

  2. Department of Mechanical Engineering, Monterrey Institute of Technology and Higher Education, Monterrey, Mexico

    Dn. Olvera

Authors
  1. E. Artetxe
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  2. Dv. Olvera
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  3. L. N. López de Lacalle
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  4. F. J. Campa
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  5. Dn. Olvera
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  6. A. Lamikiz
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Corresponding author

Correspondence to L. N. López de Lacalle.

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Artetxe, E., Olvera, D., de Lacalle, L.N.L. et al. Solid subtraction model for the surface topography prediction in flank milling of thin-walled integral blade rotors (IBRs). Int J Adv Manuf Technol 90, 741–752 (2017). https://doi.org/10.1007/s00170-016-9435-1

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  • DOI: https://doi.org/10.1007/s00170-016-9435-1

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