Tool Path Generation for Turbine Blades Machining With Twin Tool

2017 ◽  
Vol 139 (11) ◽  
Author(s):  
Dun Lu ◽  
Jun Liu ◽  
Wanhua Zhao ◽  
Bingheng Lu ◽  
Diaodiao Wu ◽  
...  
Keyword(s):  
Cutting Forces ◽  
Nuclear Power ◽  
Tool Path ◽  
Contact Point ◽  
Turbine Blades ◽  
Machining Process ◽  
Element Analysis ◽  
Machining Precision ◽  
Tool Paths ◽  
Geometric Precision

Blades are essential parts used in thermal and nuclear power generation. Its machining precision is a vital factor that influences the efficiency and life of those industries. Blades are thin-walled parts, which could easily deform under cutting forces, and hence deteriorate the machining precision. In our previous work, a milling process with twin tool for blade is proposed, in which two tools are assigned to machine the basin and dorsal surfaces simultaneously. It is expected that the cutting forces acted on the basin and dorsal surfaces can be counteracted to reduce the deformation of the blade. In this study, a method of twin-tool paths generation is developed. The tool center points and tool axis vectors are generated with consideration of the cutting forces balance, the machine tool kinematics, the surface geometric precision, and the same number of tool paths on basin and dorsal surfaces. Virtual machining, finite element analysis, and trial cutting are carried out and verified that the method which is used for generating the twin-tool paths is successful. The basin and dorsal surfaces have the same number of tool paths and tool contact point coordinates, which guarantees that the two surfaces can be completely machined and can be machined and finished simultaneously. Furthermore, the cutting forces acted on the basin and dorsal surfaces can achieve the balance along the twin-tool paths. Therefore, the deformation of a blade caused by cutting force is obviously reduced compared with a conventional machining process with a single tool.

On machining dynamics of flexible parts

2001 ◽  
Vol 215 (1) ◽  
pp. 53-59 ◽  
Author(s):  
F Abrari ◽  
M A Elbestawi ◽  
A D Spence
Keyword(s):  
Cutting Forces ◽  
Computer Aided Design ◽  
Process Model ◽  
Tool Path ◽  
Cutting Tool ◽  
Machining Process ◽  
Research Progress ◽  
Element Analysis ◽  
Flexible Parts ◽  
Five Axis

Solid modellers are now well established for computer aided design of mechanical parts. Machining applications, however, remain limited to geometric tool path planning. The physical aspects of the process are largely ignored. Success in actual machining, however, depends on consideration of cutting forces, torques, part and tool deflection, chatter, tool breakage and wear. This paper reports research progress towards a comprehensive simulation of the physical machining process of thin flexible parts. The system is based on extensions to a commercially available solid modeller. Cutting tool location data (CL-DATA) files along with an initial solid model of the workpiece are inputs. Each tool motion is segmented into short steps along the path and angular increments of spindle rotation. At each simulation step, immersion of the cutting tool teeth with the part is calculated. This information is then used by a machining process model to calculate cutting forces and tool/workpiece deflection. Up to five-axis motion is supported using a sweep representation of the tool swept volume. Flexible tools are modelled as cantilevers; flexible parts are created as solid models, are meshed and are dynamically solved using finite element analysis. The mesh is updated as material is machined away from the part.

Finite Element Analysis of Incremental Sheet Forming for Metal Sheet

2018 ◽  
Vol 783 ◽  
pp. 148-153
Author(s):  
Muhammad Sajjad ◽  
Jithin Ambarayil Joy ◽  
Dong Won Jung
Keyword(s):  
Mechanical Properties ◽  
Sheet Metal ◽  
Tool Path ◽  
Incremental Forming ◽  
Single Point ◽  
Machining Process ◽  
Machining Parameters ◽  
Forming Process ◽  
Element Analysis ◽  
Tool Diameter

Incremental sheet metal forming, is a non-conventional machining process which offers higher formability, flexibility and low cost of production than the traditional conventional forming process. Punch or tool used in this forming process consecutively forces the sheet to deform locally and ultimately gives the target profile. Various machining parameters, such as type of tool, tool path, tool size, feed rate and mechanical properties of sheet metal, like strength co-efficient, strain hardening index and ultimate tensile strength, effects the forming process and the formability of final product. In this research paper, Single Point Incremental Forming was simulated using Dassault system’s Abaqus 6.12-1 and results are obtained. Results of sheet profile and there change in thickness is investigated. For this paper, we simulated the process in abaqus. The tool diameter and rotational speed is find out for the production of parts through incremental forming. The simulation is done for two type of material with different mechanical properties. Various research papers were used to understand the process of incremental forming and its simulation.

A discrete simulation-based algorithm for the technological investigation of 2.5D milling operations

2018 ◽  
Vol 233 (1) ◽  
pp. 78-90 ◽  
Author(s):  
Adam Jacso ◽  
Tibor Szalay ◽  
Juan Carlos Jauregui ◽  
Juvenal Rodriguez Resendiz
Keyword(s):  
Tool Path ◽  
Analytical Description ◽  
Machining Process ◽  
Simulation Algorithm ◽  
Tool Paths ◽  
Milling Operations ◽  
Nc Simulation ◽  
2.5D Milling ◽  
Milling Tool ◽  
Nc Milling

Many applications are available for the syntactic and semantic verification of NC milling tool paths in simulation environments. However, these solutions – similar to the conventional tool path generation methods – are generally based on geometric considerations, and for that reason they cannot address varying cutting conditions. This paper introduces a new application of a simulation algorithm that is capable of producing all the necessary geometric information about the machining process in question for the purpose of further technological analysis. For performing such an analysis, an image space-based NC simulation algorithm is recommended, since in the case of complex tool paths it is impossible to provide an analytical description of the process of material removal. The information obtained from the simulation can be used not only for simple analyses, but also for optimisation purposes with a view to increasing machining efficiency.

scholarly journals Experimental and simulation study on chatter stability region of integral impeller with non-uniform allowance

2020 ◽  
Vol 103 (3) ◽  
pp. 003685042093341
Author(s):  
Yan Wu ◽  
Kaifa Wang ◽  
Gang Zheng ◽  
Boxin Lv ◽  
Yong He
Keyword(s):  
Natural Frequency ◽  
Stability Region ◽  
Tool Path ◽  
Surface Profile ◽  
Machining Process ◽  
Chatter Stability ◽  
Element Analysis ◽  
Impeller Blade ◽  
Five Axis ◽  
Milling Chatter

In order to accurately improve and predict chatter stability region of machining process, an optimization method of machining process with non-uniform allowance of integral impeller was proposed. The modal parameters of the workpiece process system were obtained using the finite element analysis. Based on the regenerative chatter analysis theory, a limit comparison diagram of the stability with uniform allowance and non-uniform allowance was established. The simulation results showed that the non-uniform allowance natural frequency is about 1.43 times as much as the uniform allowance natural frequency, and the machining system stiffness non-uniform allowance is twice as much as the uniform allowance, while the limit of chatter stability region is increased by 3 times. This article studied uniform allowance and non-uniform allowance of milling chatter stability with experimental method. Tool path for five-axis machining and machine tool simulation based on NX CAM were planned. The comparisons of cutting processing uniform allowance and non-uniform allowance were done, and the surface profile detection of the test part with the three-dimensional scanning was carried out. The experimental results showed that the average optimization rate for manufacturing precision of blade suction surface after optimization and pressure surface was 63.8% and 48.84%. The total experiment showed that this process optimization strategy could effectively improve the stiffness of the integral impeller blade and reduce the cutting chatter of the blade during the cutting process.

Compensating Cleanup Tool Path

1998 ◽  
Author(s):  
Xiaohong Zhu ◽  
Richard F. Riesenfeld
Keyword(s):  
Tool Path ◽  
Machining Process ◽  
Process Efficiency ◽  
Shop Floor ◽  
Machining Time ◽  
Motion Constraints ◽  
Tool Paths ◽  
Cad Cam ◽  
Computationally Intensive ◽  
Increase Tool Life

Abstract Today’s part geometries are becoming ever more complex and require more accurate tool path to manufacture. Machining process efficiency is also a major consideration for designers as well as manufacturing engineers. Although the current advanced CAD/CAM systems have greatly improved the efficiency and accuracy of machining with the introduction of Numerically–Controlled machining, excessive material may still be left on the finished part due to machining constraints, including the inaccessibility of the designed part geometry with respect the cutter, machine motion constraints like ramp angles, specific cutting patterns, etc. Polishing operations such as grinding and hand finishing are quite time consuming and expensive, and may damage the surface of the part or introduce inaccuracies because of human errors. While most of the existing machining approaches attempt to reduce such excessive restmaterials by modifying NC tool paths, none of them is satisfactory. They can be time–consuming, error prone, computationally intensive, too complicated to implement, and limited to certain problem domains. A compensating cleanup tool path will be developed in this research to automatically remove these excessive material from the finish part. This method greatly reduces the burden of hand finishing and polishing, and also reduces the error and complexities introduced in manually generating cleanup tool paths in the shop floor. More important, the tool path generated by this method will reduce the machining time, and increase tool life compared with optimized tool path which left no excessive material behind.

FE Simulation of Cryogenic Assisted Machining of Ti Alloy (Ti6AI4V)

2015 ◽  
Author(s):  
Vivek Bajpai ◽  
Ineon Lee ◽  
Hyung Wook Park
Keyword(s):  
Tool Wear ◽  
Chip Formation ◽  
Cutting Forces ◽  
Turbine Blades ◽  
Chip Morphology ◽  
Machining Process ◽  
Burr Formation ◽  
Dry Machining ◽  
Cryogenic Machining ◽  
Ti Alloys

Titanium alloys are well-known material because of the excellent mechanical/chemical properties, corrosion resistance and light weight. These alloys are widely used in the high performance applications such as; aerospace, aviation, bio-implants, turbine blades etc. Machining is commonly used to create products out of Ti alloys. Despite of good material properties, Ti alloys have low thermal conductivity, poor machinability, burr formation, high machining temperature, tool wear and poor machinability. The tool wear and high machining temperature can be controlled through coolant. Cryogenic fluid (liquid nitrogen) is a common material used as coolant in various machining process. The current work is focused on the modeling of cryogenic machining on titanium alloy (Ti6Al4V). Dry machining and cryogenic machining processes are modeled for the chip formation and cutting forces in 2D. Experimental works have been performed to validate the model based on the cutting forces and chip morphology. It is showed that the model is capturing the process, evident by the cutting forces and the chip morphology. The error in prediction is limited to 18%. Model showed that the cutting forces are increasing in cryogenic machining due to the increased strength of the workpiece at low temperature. Chip formation is well captured by the current model. Shear band width have been captured in dry machining. Chip curling has been captured at dry and cryogenic machining. It is expected that the model can further useful in the selection of cryogenic process parameter, such as, flow rate, application techniques etc.

scholarly journals Monitoring and Control of Cutting Forces in Machining Processes: A Review

2009 ◽  
Vol 3 (4) ◽  
pp. 445-456 ◽  
Author(s):  
Atsushi Matsubara ◽  
◽  
Soichi Ibaraki
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Tool Path ◽  
Machining Process ◽  
Monitoring And Control ◽  
Machining Processes ◽  
Control Schemes ◽  
Process Monitoring And Control ◽  
Optimization Schemes ◽  
And Control

Much research has gone into machining process monitoring and control. This paper reviews monitoring and control schemes of cutting force and torque. Sensors to measure cutting force and torque, as well as their indirect estimation, are reviewed. Feedback control schemes and model-based feedforward scheduling schemes of cutting forces, as well as tool path optimization schemes for cutting force regulation, are reviewed. The authors’ works are also briefly presented.

Boundary-conformed machining of turbine blades

2005 ◽  
Vol 219 (3) ◽  
pp. 255-263 ◽  
Author(s):  
S Ding ◽  
D C H Yang ◽  
Z Han
Keyword(s):  
Computer Aided Design ◽  
Tool Path ◽  
Flow Line ◽  
Turbine Blades ◽  
Free Form ◽  
Implementation Processes ◽  
Tool Marks ◽  
Tool Paths ◽  
Continuous Boundary ◽  
Free Form Surfaces

Boundary-conformed machining is a new method to mill free-form surfaces with tool paths that reflect the natural shapes of the surfaces. It is suitable for the machining of turbine blades taking into account the direction of tool marks left on the vanes. To facilitate this type of machining, this paper introduces an application of the ‘boundary-conformed algorithm’ to generate continuous boundary-conformed flow line tool paths for the milling of blade surfaces. With this approach, the initial segment of the flow line tool paths is along the top edges of the blade while the final segment follows the intersection curves between the blade and the hub surface. The intermediate segments cover the surface by changing smoothly from the initial tool path to the final tool path. The two opposite sides of the blade, which are two trimmed surfaces, are machined together continuously from top to bottom with these continuous boundary-conformed tool paths. This method has been successfully integrated into an industrial computer-aided design and manufacture system (Pro/Engineer) by using Pro/Toolkit. A detailed algorithm and implementation processes have been introduced.

A Swept Ellipse Offsetting Approach for Three-Axis Sculptured Surface Tool Path Generation

2004 ◽  
Author(s):  
Peter Jang ◽  
James A. Stori
Keyword(s):  
High Speed ◽  
Tool Path ◽  
Contact Point ◽  
Tool Path Generation ◽  
Sculptured Surface ◽  
Path Generation ◽  
Surface Machining ◽  
Tool Paths ◽  
Sculptured Surface Machining ◽  
Processing Techniques

This paper presents a new offsetting approach for tool path generation in three-axis sculptured surface machining. The approach generates tool paths with scallop, curvature, and force characteristics which make them suitable for high speed machining. An ellipse in the parametric space is used to approximate the intersection between the ball-end mill and the scallop surface for any cutter contact point on the surface. The envelope formed by these swept ellipses of varying dimension and orientation creates a constant scallop curve which is used to generate offset paths. The offset is developed incrementally, utilizing post-processing techniques to eliminate high-curvature regions in the trajectory. The offsetting approach can generate continuous spiraling trajectories which offer the benefit of minimal tool retractions. Results are shown for spiraling paths generated from both convex and non-convex boundaries.

Cutting Force Modeling When Milling Nickel-Base Superalloys

2010 ◽  
Author(s):  
Andrew J. Henderson ◽  
Cristina Bunget ◽  
Thomas R. Kurfess
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Gas Turbines ◽  
Elevated Temperatures ◽  
Base Alloy ◽  
Turbine Blades ◽  
Subsurface Damage ◽  
Machining Process ◽  
Nickel Base Superalloys ◽  
Nickel Base

Superalloys are a relatively new class of materials that exhibit high mechanical strength, ductility, creep resistance at high operating temperatures, high fatigue strength, and typically superior resistance to corrosion and oxidation even at elevated temperatures. These properties make superalloys ideal for applications in aircraft, cryogenic tanks, submarines, nuclear reactors, and petrochemical equipment. In the aerospace industry, the most commonly used superalloy is the nickel-base alloy and it accounts for 30–50% of the total material required in the manufacturing of the aircraft engine. It is used for rotating parts of gas turbines such as blades and disks, engine mounts, turbine casings and components for rocket motors and pumps. To make full use of nickel-base superalloys, a machining process must be developed that is capable of controlling and identifying tool wear, and identifying the onset of subsurface damage and controlling its formation during processing. To accomplish this, a model relating process characteristics and cutting parameters need to be developed. Due to high tool wear, the cutting forces increase drastically during machining, thus making impossible to estimate the forces with existing models. This research proposes an update to the specific cutting forces model taking into consideration rapid tool wear. As milling is the most common machining processes used to cut superalloys (e.g., turbine blades), it is specifically targeted by this research. Experiments were conducted under different cutting conditions to observe the cutting characteristics of nickel-base superalloys. Empirical observations were used to formulate updated coefficients. Later this model will be applied for real-time control of the process results, such as geometry, tool wear and subsurface damage, and also for estimation and control of other quantities such as force, deflection, surface quality and energy consumed. This will provide new insights into machining these advanced alloys.

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