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Parametric design and surface topography analysis of turbine blade processing by turn-milling based on CAM

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Abstract

The design and manufacturing level of the blade largely affects the performance of the aero engine. In this paper, the blade is taken as the research object, focusing on its design and processing. On the one hand, based on the mathematical method of fifth-order polynomial, a GUI module for parameterized design of different blade profiles is established. On the other hand, in CAM environment, the procedure division of turn-milling the blade, the generation of tool path, the optimization of NC program and the simulation of machining process are completed. On this basis, the experiment of machining the part by turn-milling is finished. In addition, in order to study the quality of the machined surface, a mathematical model for predicting the surface topography of turn-milling blade is established based on the surface unfolding and meshing of the workpiece. Then, the effects of the number of cutter teeth, tool rotation speed, feed rate, and the cutter radius on surface topography are analyzed qualitatively. Besides, the maximum surface residual height is used as an index to quantitatively compare the influence of different parameters on surface topography. Finally, the simulation reliability is verified by comparing with the experimental surface.

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Abbreviations

b :

Chord length (mm)

f max :

Maximum deflection

β 1k :

Leading edge angle (°)

β 2k :

Trailing edge angle (°)

β 1 :

Import (front) structural angle (°)

β 2 :

Exit (trailing edge) structural angle (°)

β m :

Installation angle (°)

β o :

Outlet angle (°)

τ :

Cascade solidity, τ = b/t

i :

Attack angle, the difference between β1 and β1k. (°)

δ :

Bend angle, the sum of β1k and β2k. (°)

t :

Grid pitch (mm)

r 1 :

Leading-edge radius (mm)

r 2 :

Trailing-edge radius (mm)

C max :

Maximum thickness (mm)

φ 1 :

Leading edge wedge angle of inlet edge (°)

φ 2 :

Leading edge wedge angle of exit edge (°)

l :

Throat width (mm)

S :

Axial width of blade profile (mm)

N b :

Number of blades

n t :

Tool rotation speed (rpm)

n w :

Workpiece rotation speed (rpm)

n w, relative :

Relative speed of the workpiece (rpm)

n w, ave :

The average value of relative rotational speed of workpiece (rpm)

a p :

Cutting depth (mm)

R t :

Tool radius (mm)

R w :

Workpiece radius (mm)

∆ϕ:

Instantaneous rotation angle of workpiece

ΔW:

Residual height of the workpiece surface after each feed of the tool (μm)

W :

Residual height of the machined surface (μm)

R s :

Instantaneous radius at the edge of blade section (mm)

c :

Total feed rate (mm/z)

c a :

Axial feed per tooth (mm/z)

c z :

Circumferential feed per tooth (mm/z)

f a :

Axial feed per second (mm/s)

N t :

Number of cutter teeth

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Funding

This work was supported by the National Natural Science Foundation of China (NSFC; 51475087).

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Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Northeastern University, Shenyang, 110819, China

    Jinsheng Ning & Lida Zhu

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  1. Jinsheng Ning
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  2. Lida Zhu
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Correspondence to Lida Zhu.

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Ning, J., Zhu, L. Parametric design and surface topography analysis of turbine blade processing by turn-milling based on CAM. Int J Adv Manuf Technol 104, 3977–3990 (2019). https://doi.org/10.1007/s00170-019-04037-x

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  • DOI: https://doi.org/10.1007/s00170-019-04037-x

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