Five-axis milling of sculptured surfaces of the turbine blade

2018 ◽  
Vol 90 (1) ◽  
pp. 146-157 ◽  
Author(s):  
Michal Gdula ◽  
Jan Burek ◽  
Lukasz Zylka ◽  
Marcin Plodzien
Keyword(s):  
Turbine Blade ◽  
Turbine Blades ◽  
Dimensional Accuracy ◽  
Milling Process ◽  
Radius Of Curvature ◽  
Sculptured Surfaces ◽  
Axis Orientation ◽  
Content Type ◽  
Five Axes ◽  
Toroidal Cutter

Purpose The purpose of this paper is to determine the influence of a toroidal cutter axis orientation and a variable radius of curvature of the machined contour of sculptured surface on the five-axes milling process. Simulation and experimental research performed in this work are aimed to determine the relationship between the parameters of five-axes milling process and the shape and dimensional accuracy of curved outline of Inconel 718 alloy workpiece. Design/methodology/approach A subject of research are sculptured surfaces of the turbine blade. Simulation research was performed using the method of direct mapping tools in the CAD environment. The machining research was carried out with the use of multi-axis machining center DMU 100 monoBLOCK DMG, equipped with rotating dynamometer to measure the components of the cutting force. To control the shape and dimensional accuracy, the coordinate measuring machine ZEISS ACCURA II was used. Findings In this paper, the effect of the toroidal cutter axis orientation and the variable radius of curvature of the machined contour on the parameters of five-axes milling process and the accuracy of the sculptured surfaces was determined. Practical implications Five-axes milling with the use of a toroidal cutter is found in the aviation industry, where sculptured surfaces of the turbine blades are machined. The results of the research allow more precise planning of five-axes milling and increase of the turbine blades accuracy. Originality/value This paper significantly complements the current state of knowledge in the field of five-axes milling of turbine blades in terms of their accuracy.

scholarly journals Cutting layer and cutting forces in a 5-axis milling of sculptured surfaces using the toroidal cutter

2017 ◽  
Vol 4 (17) ◽  
pp. 98-122
Author(s):  
Michal GDULA ◽  
Jan BUREK
Keyword(s):  
Turbine Blade ◽  
Convex Surface ◽  
Experimental Studies ◽  
Surface Profile ◽  
Radius Of Curvature ◽  
Geometrical Parameters ◽  
Inconel 718 Alloy ◽  
Axis Orientation ◽  
Five Axis ◽  
Toroidal Cutter

The purpose of this article was to evaluate the significance of the influence of five- axis orientation parameters of a toroidal cutter axis and the geometrical parameters of the machined sculptured surface on the intersection of the cut layer in a 5-axis machining. An impact assessment was performed by simulating concave-convex and convex-concave surfaces using a discrete method of direct transformation in a CAD environment. It was shown that only the radius of curvature of the surface in the feed direction and the angle of the tool axis affected the change in the intersection of the cutting layer. Subsequently, experimental tests were conducted that aimed at determining the mathematical models of the influence of these important parameters on the components of the cutting force. The object of the experimental studies was a convex and concave surface of a turbine blade of Inconel 718 alloy. The R300-016B20L-08L Sandvik Coromant toroid cutter was used for the tests. Based on the results of the study it was found that the lead angle in the machining of the convex surface and concave turbine blade should be continuously varied with the change of radius of curvature in the direction of the machined surface profile

scholarly journals Effect of the lead angle and the radius of curvature on the cutting forces in a 5-axis milling of sculptured surfaces

Mechanik ◽  
2018 ◽  
Vol 91 (1) ◽  
pp. 18-22
Author(s):  
Michał Gdula ◽  
Jan Burek
Keyword(s):  
Turbine Blade ◽  
Convex Surface ◽  
Experimental Studies ◽  
Surface Profile ◽  
Radius Of Curvature ◽  
Sculptured Surface ◽  
Sculptured Surfaces ◽  
Inconel 718 Alloy ◽  
Machined Surface ◽  
Lead Angle

Experimental studies are presented, were conducted that aimed at determining the mathematical models of the influence of the lead angle and the radius of curvature of the profile of machined sculptured surface on the components of the cutting force. The object of the experimental studies was a convex and concave surface of a turbine blade of Inconel 718 alloy. The toroid cutter was used for the tests. Based on the results of the study it was found that the lead angle in the machining of the convex surface and concave turbine blade should be continuously varied with the change of radius of curvature in the direction of the machined surface profile.

scholarly journals Effect of kinematic and geometric parameters on the cut layer in a 5-axis machining of the sculptured surfaces

Mechanik ◽  
2017 ◽  
Vol 90 (12) ◽  
pp. 1116-1119
Author(s):  
Michał Gdula ◽  
Jan Burek
Keyword(s):  
Geometric Parameters ◽  
Curvature Radius ◽  
Sculptured Surface ◽  
Simulation Studies ◽  
Sculptured Surfaces ◽  
Axis Orientation ◽  
Convex Surfaces ◽  
Orientation Parameters ◽  
Toroidal Cutter

Results of simulation studies made using the direct CAD method are presented. The significance of the influence of the toroidal cutter axis orientation parameters and curvature radius of the sculptured surface on the cut layer in a 5-axis milling of the convex-concave and concave-convex surfaces, was assessed.

Efficient structural analysis of gas turbine blades

2018 ◽  
Vol 90 (9) ◽  
pp. 1305-1316
Author(s):  
Timo Rogge ◽  
Ricarda Berger ◽  
Linus Pohle ◽  
Raimund Rolfes ◽  
Jörg Wallaschek
Keyword(s):  
Structural Analysis ◽  
Gas Turbine ◽  
Turbine Blade ◽  
Turbine Blades ◽  
Element Model ◽  
Gas Turbine Blade ◽  
Quality Of Results ◽  
Content Type ◽  
Gas Turbine Blades

Purpose The purpose of this study a fast procedure for the structural analysis of gas turbine blades in aircraft engines. In this connection, investigations on the behavior of gas turbine blades concentrate on the analysis and evaluation of starting dynamics and fatigue strength. Besides, the influence of structural mistuning on the vibration characteristics of the single blade is analyzed and discussed. Design/methodology/approach A basic computation cycle is generated from a flight profile to describe the operating history of the gas turbine blade properly. Within an approximation approach for high-frequency vibrations, maximum vibration amplitudes are computed by superposition of stationary frequency responses by means of weighting functions. In addition, a two-way coupling approach determines the influence of structural mistuning on the vibration of a single blade. Fatigue strength of gas turbine blades is analyzed with a semi-analytical approach. The progressive damage analysis is based on MINER’s damage accumulation assuming a quasi-stable behavior of the structure. Findings The application to a gas turbine blade shows the computational capabilities of the approach presented. Structural characteristics are obtained by robust and stable computations using a detailed finite element model considering different load conditions. A high quality of results is realized while reducing the numerical costs significantly. Research limitations/implications The method used for analyzing the starting dynamics is based on the assumption of a quasi-static state. For structures with a sufficiently high stiffness, such as the gas turbine blades in the present work, this procedure is justified. The fatigue damage approach relies on the existence of a quasi-stable cyclic stress condition, which in general occurs for isotropic materials, as is the case for gas turbine blades. Practical implications Owing to the use of efficient analysis methods, a fast evaluation of the gas turbine blade within a stochastic analysis is feasible. Originality/value The fast numerical methods and the use of the full finite element model enable performing a structural analysis of any blade structure with a high quality of results.

Surface-Surface Contact in 5-Axis NC Machining of Sculptured Surfaces Using Anural Cutter

2010 ◽  
Vol 37-38 ◽  
pp. 1376-1379
Author(s):  
Quan Hong Liu ◽  
Hu Ran Liu
Keyword(s):  
Turbine Blades ◽  
Measurement Data ◽  
Sculptured Surfaces ◽  
Original Design ◽  
Axis Orientation ◽  
Marine Propellers ◽  
Surface Patches ◽  
Milling Tool ◽  
Swept Surface ◽  
Product Design Process

Sculptured surface are used in a wide variety of applications in the automotive, aerospace and ship building industries, such as turbine blades, impeller and marine propellers. The original design concept is often embodied in a physical model, perhaps sculpted from clay by a skilled artisan, from which measurement data is scanned. Surfaces are fitted to the scanned data, and a mathematically precise description is then available for subsequent steps in the product-design process. Parametric forms such as the well known Bezier, B-spline and NURBS type usually mathematically define the surfaces. Typically, a design is composed of number of parametric surface patches. This is the highly effective method. In this paper an innovative theory for machining complicated surface is presented. By using an anural milling tool instead of ball-end mill or the flat-ended tool, and by adjusting the axis of cutter relative to the surface, the two surfaces, the swept surface and the required surface, have the same curvatures, up to as high as 3rd order. Through the deduction of differential equation, some theory on partial touching between surfaces and surfaces when manufacturing has been explored. The problem of axis orientation under this condition has also been discussed clearly. The outside of the circular tool is a surface; the surface to be machined is a groove, which can be represented by its transverse line. In this case the problem is attributed to the contact between surface and curve.

Influence of milling toolpaths in machining of the turbine blade

2019 ◽  
Vol 91 (10) ◽  
pp. 1327-1339
Author(s):  
Seyedamin Jarolmasjed ◽  
Behnam Davoodi ◽  
Babak Pourebrahim Alamdari
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Turbine Blade ◽  
Tool Life ◽  
Surface Texture ◽  
Turbine Blades ◽  
Measuring System ◽  
Machining Processes ◽  
Machined Surface ◽  
Content Type

Purpose The purpose of this paper is to machine the pressure surface of the turbine blade made of A286 iron-based superalloy by using four directions of raster strategy, including horizontal upward, horizontal downward, vertical upward and vertical downward, to achieve appropriate surface roughness and to investigate the tool wear in each strategy. Design/methodology/approach In this study, all cutting tests were performed by DAHLIH-MCV 1020 BA vertical 3-axis machining center with ball nose end mill. After milling by each strategy, according to the surface slope, the surface was divided into 27 meshes, and roughness of surface was studied and compared. Roughness measuring after machining was implemented by using portable Mahr ps1 roughness tester, and surface texture was photographed by CCD 100× optical zoom camera. Also, to measure tool flank wear in each strategy as an indication of tool life, the surface of workpiece was divided into four equal areas. The wear of the inserts was measured by ARCS vertical non-contact measuring system at the end of each area. Findings The results indicate that cutting directions and toolpath strategies have significant influence on tool wear and surface roughness in machining processes and that they can be taken into consideration individually as determinative parameters. In this case, the most uniform surface texture and the lowest surface roughness are obtained by using horizontal downward direction; in addition, abrasion is a dominant tool wear mechanism in all experiments, and tool wear in the horizontal downward is lower than other strategies. Practical implications Machining of turbine blades or other airfoil-shaped workpieces is quite common in manufacturing aerospace and aircraft products. The results of this research contribute to increasing quality of machined surface and tool life in machining of turbine blade. Originality/value This work proves the significance of milling strategies in machining of the turbine blade made of A286 superalloy and, consequently, exhibits the proper strategy in terms of surface roughness and tool life. Also, this work explains and elaborates the behavior of A286 superalloy in machining processes, which has not been studied much in recent research works.

Thermal radiation effects on creep behavior of the turbine blade

2016 ◽  
Vol 12 (2) ◽  
pp. 291-314 ◽  
Author(s):  
Mohammad yaghoub Abdollahzadeh Jamalabadi
Keyword(s):  
Steady State ◽  
Thermal Radiation ◽  
Gas Turbine ◽  
Turbine Blade ◽  
Creep Behavior ◽  
Radiation Effects ◽  
Kinematic Hardening ◽  
Turbine Blades ◽  
Turbine Engines ◽  
Content Type

Purpose – The purpose of this paper is to find the time dependent thermal creep stress relaxation of a turbine blade and to investigate the effect thermal radiation of the adjacent turbine blades on the temperature distribution of turbine blade and creep relaxation. Design/methodology/approach – For this analysis, the creep flow behavior of Moly Ascoloy in operational temperature of gas turbine in full scale geometry is studied for various thermal radiation properties. The commercial software is used to pursue a coupled fields analysis for turbine blades in view of the structural force, materials kinematic hardening, and steady-state temperature field. Findings – During steady-state operation, the thermal stress was found to be decreasing, whereas by considering the thermal radiation this rate was noticed to increase slightly. Also by increase of the distance between stator blades the thermal radiation effect is diminished. Finally, by decrease of the blade distance the failure probability and creep plastic deformation decrease. Research limitations/implications – This paper describes the effect of thermal radiation in thermal-structural analysis of the gas turbine stator blade made of the super-alloy M-152. Practical implications – Blade failures in gas turbine engines often lead to loss of all downstream stages and can have a dramatic effect on the availability of the turbine engines. There are many components in a gas turbine engine, but its performance is highly profound to only a few. The majority of these are hotter end rotating components. Social implications – Three-dimensional finite element thermal and stress analyses of the blade were carried out for the steady-state full-load operation. Originality/value – In the previous works the thermal radiation effects on creep behavior of the turbine blade have not performed.

scholarly journals Method of controlling the lead angle of the toroidal cutter axis in 5-axis machining of the turbine blade

Mechanik ◽  
2017 ◽  
Vol 90 (8-9) ◽  
pp. 710-712 ◽  
Author(s):  
Michał Gdula ◽  
Jan Burek ◽  
Marcin Żółkoś
Keyword(s):  
Turbine Blade ◽  
Control Method ◽  
Classical Method ◽  
Surface Profile ◽  
Radius Of Curvature ◽  
Sculptured Surface ◽  
Lead Angle ◽  
Toroidal Cutter

Presented is the own concept control method an lead angle axis of the toroidal cutter, depending on the radius of curvature of the machined sculptured surface profile. The method verified on the example machining of the turbine blade. In order to compare the effects of this method, to the classical method (without adaptation lead angle), tests were performed for both these methods.

scholarly journals Turbine Blade Three-Wavelength Radiation Temperature Measurement Method Based on Reflection Error Correction

2021 ◽  
Vol 11 (9) ◽  
pp. 3913
Author(s):  
Kaifeng Zheng ◽  
Jinguang Lü ◽  
Yingze Zhao ◽  
Jin Tao ◽  
Yuxin Qin ◽  
...  
Keyword(s):  
Temperature Measurement ◽  
Turbine Blade ◽  
Measurement Method ◽  
Turbine Blades ◽  
Target Surface ◽  
Maximum Error ◽  
Radiation Temperature ◽  
Average Error ◽  
Real Surface ◽  
Wavelength Radiation

The turbine blade is a key component in an aeroengine. Currently, measuring the turbine blade radiation temperature always requires obtaining the emissivity of the target surface in advance. However, changes in the emissivity and the reflected ambient radiation cause large errors in measurement results. In this paper, a three-wavelength radiation temperature measurement method was developed, without known emissivity, for reflection correction. Firstly, a three-dimensional dynamic reflection model of the turbine blade was established to describe the ambient radiation of the target blade based on the real surface of the engine turbine blade. Secondly, based on the reflection correction model, a three-wavelength radiation temperature measurement algorithm, independent of surface emissivity, was proposed to improve the measurement accuracy of the turbine blade radiation temperature in the engine. Finally, an experimental platform was built to verify the temperature measurement method. Compared with three conventional colorimetric methods, this method achieved an improved performance on blade temperature measurement, demonstrating a decline in the maximum error from 6.09% to 2.13% and in the average error from 2.82% to 1.20%. The proposed method would benefit the accuracy in the high-temperature measurement of turbine blades.

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