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

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.

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

Mechanik ◽

10.17814/mechanik.2018.1.2 ◽

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.

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

Journal of Machine Engineering ◽

10.5604/01.3001.0010.7009 ◽

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

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Five-axis milling of sculptured surfaces of the turbine blade

Aircraft Engineering and Aerospace Technology ◽

10.1108/aeat-11-2015-0242 ◽

2018 ◽

Vol 90 (1) ◽

pp. 146-157 ◽

Cited By ~ 3

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.

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Effect of toroidal cutter axis orientation on the cutting forces in the five-axis machining of sculptured surface turbine blade of INCONEL 718

Mechanik ◽

10.17814/mechanik.2015.8-9.489 ◽

2015 ◽

pp. 731/764-731/774

Author(s):

Jan Burek ◽

Łukasz Żyłka ◽

Michał Gdula ◽

Marcin Płodzień

Keyword(s):

Turbine Blade ◽

Cutting Forces ◽

Inconel 718 ◽

Sculptured Surface ◽

Axis Orientation ◽

Five Axis ◽

Toroidal Cutter

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Toolpath Generation for Four-Axis Rough Milling of Sculptured Surface Turbine Blade

Intelligent Robotics and Applications - Lecture Notes in Computer Science ◽

10.1007/978-3-540-88518-4_95 ◽

2008 ◽

pp. 887-895 ◽

Cited By ~ 2

Author(s):

Ming Luo ◽

Baohai Wu ◽

Dinghua Zhang ◽

Shan Li ◽

Ying Zhang

Keyword(s):

Turbine Blade ◽

Sculptured Surface ◽

Toolpath Generation ◽

Rough Milling

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Surface Topography Changes in Polymer-Metal Sliding—II

Journal of Lubrication Technology ◽

10.1115/1.3254660 ◽

1983 ◽

Vol 105 (4) ◽

pp. 526-531 ◽

Cited By ~ 2

Author(s):

V. K. Jain ◽

S. Bahadur

Keyword(s):

Surface Roughness ◽

Standard Deviation ◽

High Density Polyethylene ◽

Surface Profile ◽

Data Acquisition System ◽

Radius Of Curvature ◽

Roughness Parameters ◽

Poly Vinyl Chloride ◽

Polymer Metal

The variation in the surface topographical parameters for the case of sliding between high density polyethylene and poly(vinyl chloride) pin ends and a steel disk periphery was investigated. Sliding surface profile ordinate data were obtained at 2μm intervals using a data acquisition system, both along and perpendicular to the direction of sliding. A number of surface roughness parameters, viz., the r.m.s. and c.l.a. roughness, the slope, density, and radius of curvature of asperities, the standard deviation and distribution of profile ordinates, slopes, radii of curvatures and heights of asperities were calculated using a Fortran IV computer program. The analysis showed that the surface parameters undergo a marked variation during the early part of sliding, but the variation is statistically insignificant during the later part. It was found that the standard deviation of peak heights can be approximated by the r.m.s. surface roughness.

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Crater Geometry and Volume From Electro-Discharge Machined Surface Profiles by Data Dependent Systems

Journal of Engineering for Industry ◽

10.1115/1.3183867 ◽

1980 ◽

Vol 102 (4) ◽

pp. 289-295 ◽

Cited By ~ 9

Author(s):

S. M. Pandit ◽

K. P. Rajurkar

Keyword(s):

Impulse Response Function ◽

Surface Profile ◽

Operating Conditions ◽

Surface Generation ◽

Radius Of Curvature ◽

Regression Equations ◽

Machining Time ◽

Machined Surface ◽

Depth Ratio ◽

Single Discharge

This paper applies a recently developed methodology called Data Dependent Systems to model and analyse the process of Electro-Discharge Machined (EDM) surface generation. A first order stochastic differential equation is developed and physically interpreted from the EDM surface profile measurements under varying pulse duration and machining time. The impulse response function of this model is used to define a characteristic crater geometry. The depth and diameter to depth ratio of such a crater is determined and employed in deriving the radius of curvature and the volume. Experimental measurements are utilized to illustrate the development of regression equations and nomograms, useful in practice to obtain surfaces with desired geometry. It is shown that the depth diameter to depth ratio, and volume of the characteristic craters obtained from actual multiple discharge situation under operating conditions agree fairly well with the past single discharge physics investigations.

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Efficiency increase in profile deep grinding of turbine blade on NC multi-axes machines

Science intensive technologies in mechanical engineering ◽

10.12737/article_5aacd857ebb357.07694535 ◽

2018 ◽

Vol 2018 (4) ◽

pp. 21-29

Author(s):

Владимир Макаров ◽

Vladimir Makarov ◽

Сергей Никитин ◽

Sergey Nikitin

Keyword(s):

Cutting Force ◽

Turbine Blade ◽

Fatigue Resistance ◽

Material Removal ◽

Surface Profile ◽

Dynamic Processes ◽

Efficiency Increase ◽

Deep Profile ◽

Cutting Modes ◽

Elementary Area

The paper reports the procedure of a cutting mode purpose at deep profile grinding on NC multi-axes machines on the basis of the modeling of thermo-dynamic processes in cutting areas with the purpose of ensuring turbine blade fatigue resistance. There are shown simulators allowing the definition and prediction of the dynamics of elastic, thermal and working processes in a technological system, material removal, cutting force, temperatures in the area of cutting and roughness of each elementary area of the surface profile on the basis of cutting modes, disk characteristics.

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

Mechanik ◽

10.17814/mechanik.2017.12.191 ◽

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.

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