Skip to main content
SpringerLink
Log in

A look-ahead transition algorithm and jump motion planning in multi-axis EDM for shrouded blisks

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

Abstract

Shrouded blisks play a vital role in aero and rocket engines. Multi-axis EDM is regarded as the most commonly used manufacturing method for shrouded blisks. For a linear jump path, the jump motion only needs to consider the starting and end point of the jump and there is no direction change during the jump. However, when dealing with multi-axis jump motions, the path of a jump motion is a curve which is represented by a number of line segments. For this case, the jump speed of an electrode will change abruptly in terms of direction and magnitude during the jump motion. In this paper, multi-axis corner rounding solution (MCRS) is proposed to smooth multi-axis jump paths. Two three-dimensional subspaces, a linear subspace and a rotary subspace, are built to describe six-axis jump paths for a six-axis EDM machine tool. A three-axis jump path smoothing solution can be applied for the subpath in each subspace. By using a bidirectional scanning method as well as an S-shaped profile, the smoothness of the multi-axis feedrate schedule is obtained. Simulation results show that the MCRS achieves a smoother scheduled feedrate profile as well as a higher efficiency. Experimental results show that the machining time can be decreased by 19.68% with the use of the MCRS.

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

Similar content being viewed by others

References

  1. Yoon S, Curtis E, Denton J, Longley J (2014) The effect of clearance on shrouded and unshrouded turbines at two levels of reaction[J]. J Turbomach 136(2):021013

    Article  Google Scholar 

  2. Harada H (1985) Performance characteristics of shrouded and unshrouded impellers of a centrifugal compressor. J Eng Gas Turbines Power 107(2):85–85

    Article  Google Scholar 

  3. Zhan H, Zhao W, Wang G (2000) Manufacturing turbine blisks. Aircr Eng Aerosp Technol 72(3):247–252

    Article  Google Scholar 

  4. Takeuchi H, Kunieda M (2007) Relation between debris concentration and discharge gap width in EDM process. Denki Kako Gakkaishi 41(98):156–162

    Article  Google Scholar 

  5. Havakawa S, Itoigawa TDF, Nakamura T (2010) Observation of flying debris scattered from discharge point in EDM process. In: Proceedings of the 16th international symposium on electromachining

  6. Beudaert X, Lavernhe S, Tournier C (2013) 5-axis local corner rounding of linear tool path discontinuities. Int J Mach Tools Manuf 73(10):9–16

    Article  Google Scholar 

  7. Li G, Zhao W, Wang Z, Wu X (2007) A special CAD/CAM software for electro-discharge machining of shrouded turbine blisks[J]. Adv Manuf 11(1):74–78

    Google Scholar 

  8. Liu X, Kang X, Xi X, Liang W, Zhao W (2012) Electrode feed path planning for multi-axis EDM of integral shrouded impeller. Int J Adv Manuf Technol 68(5-8):1697–1706

    Article  Google Scholar 

  9. Liu X, Kang X, Zhao W, Liang W (2013) Electrode feeding path searching for 5-axis EDN of integral shrouded blisks. Procedia Cirp 6(8):107–111

    Article  Google Scholar 

  10. Ayesta I, Izquierdo B, Ramos JM, Ramos JM, Plaza S, Pombo I et al (2016) Optimum electrode path generation for EDM manufacturing of aerospace components. Robot Comput Integr Manuf 37(C):273–281

    Article  Google Scholar 

  11. Kang X, Liang W, Yang Y, Zhao W (2017) Maximum free distance method for electrode feeding path planning in EDM machining of integral shrouded blisks. Precision Engineering

  12. Zhao H, Zhu L (2013) A real-time look-ahead interpolation methodology with curvature-continuous B-spline transition scheme for CNC machining of short line segments. Int J Mach Tools Manuf 65(2):88–98

    Article  Google Scholar 

  13. Liao YS, Wu PS, Liang FY (2013) Study of debris exclusion effect in linear motor equipped die-sinking EDM process. Procedia Cirp 6(7):123–128

    Article  Google Scholar 

  14. Cetin S, Okada A, Uno Y (2003) Electrode jump motion in linear motor equipped die-sinking EDM. J Manuf Sci Eng 125(4):809–815

    Article  Google Scholar 

  15. Liang S, Zhao W, Kang X (2012) High-speed jump motion control system for electro-discharge machining based on programmable multi-axis controller. J Shanghai Jiaotong Univ 46(9):1476– 1481

    Google Scholar 

  16. Liu HD, Xi XC, Liang W, Chen M, Chen H, Zhao WS (2018) A look-ahead transition algorithm for jump motions with short line segments in EDM. Int J Adv Manuf Technol 95:1409–1419

    Article  Google Scholar 

  17. Tsai MS, Nien HW, Yau HT (2010) Development of a real-time look-ahead interpolation methodology with spline-fitting technique for high-speed machining. Int J Adv Manuf Technol 47(5-8):621–638

    Article  Google Scholar 

  18. Annoni M, Bardine A, Campanelli S, Foglia P, Prete CA (2012) A real-time configurable NURBS interpolator with bounded acceleration, jerk and chord error. Comput-Aided Des 44(6):509–521

    Article  Google Scholar 

  19. Zhang LB, You YP, He J et al. (2011) The transition algorithm based on parametric spline curve for high-speed machining of continuous short line segments[J]. Int J Adv Manuf Technol 52(1-4):245–254

    Article  Google Scholar 

  20. Walton DJ, Meek DS (2009) G 2 blends of linear segments with cubics and Pythagorean-hodograph quintics. Int J Comput Math 86(9):1498–1511

    Article  MathSciNet  MATH  Google Scholar 

  21. Langeron JM, Duc E, Lartigue C, Bourdet P (2004) A new format for 5-axis tool path computation, using Bspline curves. Comput Aided Des 36(12):1219–1229

    Article  Google Scholar 

  22. Shi J, Bi QZ, Zhu LM, Wang YH (2015) Corner rounding of linear five-axis tool path by dual PH curves blending. Int J Mach Tools Manuf 88:223–236

    Article  Google Scholar 

  23. Zhang J, Zhang L, Zhang K, Mao J (2016) Double NURBS trajectory generation and synchronous interpolation for five-axis machining based on dual quaternion algorithm. Int J Adv Manuf Technol 83(9-12):2015–2025

    Article  Google Scholar 

  24. Zhang X, YU D, Hang W (2010) Corner curve transition interpolation algorithm for high speed machining of micro-line segment. J Mech Eng 46(19):183

    Article  Google Scholar 

  25. Chen H, Xue-Cheng XI, Zhao W (2016) Angular movement ratio planning of the rotary axes for shrouded blisks multi-axis EDM. Procedia Cirp 42:206–209

    Article  Google Scholar 

  26. Chen H, Xi XC, Zhao W, Chen M (2016) Feedrate planning for synchronized movements involving rotary axes in multi-axis EDM for shrouded blisks. Int J Adv Manuf Technol 90(9-12):2645–2654

    Article  Google Scholar 

  27. Chen H (2017) Kinematics planning of multi-axis EDM based on digitizer/player architecture[D]. Shanghai Jiao Tong University, Shanghai

    Google Scholar 

  28. Lee AC, Lin MT, Pan YR et al (2011) The feedrate scheduling of NURBS interpolator for CNC machine tools[J]. Comput Aided Des 43(6):612C628

    Article  Google Scholar 

  29. Zhao W, Chen M, Chen H (2013) A novel trajectory interpolation algorithm for WEDM—Unit Generalized Arc Length Increment Method. Procedia Cirp 6(7):255–260

    Article  Google Scholar 

Download references

Funding

This research is financially supported by the National Natural Science Foundation of China (Grant No. 51675340), Shenzhen Basic Research Program (Grant No. JCYJ20170811160440239), National Science and Technology Major Project(Grant No. 2014ZX04001061), and China Postdoctoral Science Foundation (Grant No. 2017M621460).

Author information

Authors and Affiliations

  1. Shenzhen Research institute, State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, China

    Hong-Da Liu, Xue-Cheng Xi, Mo Chen & Wan-Sheng Zhao

Authors
  1. Hong-Da Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Xue-Cheng Xi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Mo Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Wan-Sheng Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Xue-Cheng Xi.

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

Liu, HD., Xi, XC., Chen, M. et al. A look-ahead transition algorithm and jump motion planning in multi-axis EDM for shrouded blisks. Int J Adv Manuf Technol 98, 947–958 (2018). https://doi.org/10.1007/s00170-018-2286-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-2286-1

Keywords

Search

Navigation