Purpose -The purpose of this paper is to present the advantages of computer-aided design/rapid prototyping (CAD/RP) usage in designing and manufacturing of the core models used for precise casting with direct and single solidification of aircraft engine turbine blade cores. Design/methodology/approach -The process of modelling three-dimensional CAD geometry of research blade in relation to the model of the core was presented with different wax types used in the RP technique. Findings -The geometry of the blade model has been designed in a way which allows making a silicon mould on the basis of a base prototype in the process of rapid tooling (RP/RT). Filing by different wax types was investigated in mean of the impact on filling accuracy of the mould cavity. Originality/value -The resulting models were used to make ceramic moulds and carry further work on the development of casting technology in the process of directional solidification and single crystal solidification of core blades of aircraft engines.

The objective of this publication is to present a quality control methodology for additive manufacturing products made of polymer materials, where the methodology varies depending on the intended use. The models presented in this paper are divided into those that are manufactured for the purpose of visual presentation and those that directly serve the needs of the manufacturing process. The authors also a propose a comprehensive control system for the additive manufacturing process to meet the needs of Industry 4.0. Depending on the intended use of the models, the quality control process is divided into three stages: data control, manufacturing control, and post-processing control. Research models were made from the following materials: RGD 720 photopolymer resin (PolyJet method), ABS M30 thermoplastic (FDM method), E-Partial photopolymer resin (DLP method), PLA thermoplastic (FFF method), and ABS thermoplastic (MEM method). The applied measuring tools had an accuracy of at least an order of magnitude higher than that of the manufacturing technologies used. The results show that the PolyJet method is the most accurate, and the MEM method is the least accurate. The findings also confirm that the selection of materials, 3D printing methods, and measurement methods should always account not only for the specificity and purpose of the model but also for economic aspects, as not all products require high accuracy and durability.

Oceniano właściwości mechaniczne oraz przetwórcze kompozytów otrzymanych na osnowie żywicy epoksydowej (EP) i napełniaczy hybrydowych, zwłaszcza pod kątem ich zastosowania w metodach szybkiego prototypowania do wytwarzania modeli kół zębatych. Weryfikację dokładności odwzorowania kształtu geometrycznego modelu wykonano za pomocą bezstykowego systemu optycznego opartego na współrzędnościowym skanerze optycznym ATOS Triple Scan II Blue Light firmy GOM. Wytworzone kompozyty hybrydowe wykazywały znacznie lepsze właściwości mechaniczne niż nienapełniona żywica epoksydowa. Dzięki wprowadzeniu do osnowy EP hybrydowych napełniaczy uzyskano ograniczenie skurczu promieniowego i osiowego, co wpłynęło na radykalną poprawę dokładności odwzorcowania kształtu geometrycznego odlewanych kół zębatych. Słowa kluczowe: kompozyty polimerowe, skaner optyczny, dokładność geometryczna, modele kół zębatych, napełniacze. Application of ATOS II optical system in the techniques of rapid prototyping of epoxy resin-based gear models Abstract: The mechanical and processing properties of composites with epoxy resin (EP) matrix and hybrid fillers, especially with regard to their use in rapid prototyping methods for the preparation of gear models, were evaluated. The accuracy assessment of geometric model shape mapping was performed using a non-contact optical system based on the coordinate optical scanner ATOS Triple Scan II Blue Light from GOM company. The produced hybrid composites show much better mechanical properties than those of unfilled epoxy resin. By introducing the hybrid fillers into EP matrix, a reduction in radial and axial shrinkage was achieved, which led to a radical improvement in the accuracy of geometric shape mapping of gear castings.

Purpose The purpose of this paper is to present the methodology for manufacturing of aircraft transmission gears using incremental method of rapid prototyping (RP) – direct metal laser sintering (DMLS). The production of prototypes from metallic powders using described system allows the execution of final elements of complex structures with additional economic impacts. Design/methodology/approach The paper describes the use of selective laser sintering method (DMLS) by EOS Company. Whole chain of production of prototype is presented with the addition of geometric accuracy measurements by blue light laser device. Findings Presented in the research analysis of SLS/SLM technologies as rapid manufacturing systems shows that they can be applied in the production of prototypes used in the manufacturing process of gears for propulsion systems in aviation industry. Also, very important is the geometrical accuracy of gear prototypes produced by incremental methods. It determines subsequent treatment steps for aircraft propulsion system gears. Practical Implications The use of RP techniques as an alternative for conventionally used manufacturing method has mainly an economic impact related to the cost of time-consuming process and amount of defected elements appearing in serial production. Originality/value This paper presents possibility to use RP – DMLS system – for propulsion elements of aircraft structure. This research is original because of the complex description of the whole chain of manufacturing process. Additionally, geometrical accuracy measurement methodology by blue light presented with the RP method of manufacturing gives the research a unique characteristic.

Purpose The purpose of this paper is to present coordinate measuring system possibilities in the meaning of the geometric accuracy assessment of hot zone elements in aircraft engines. The aim of the paper is to prove that this method, which uses blue light and is most sufficient and cost-saving method, can to be used in the production line for serial manufacturing of elements, for which a high level of accuracy is required. Design/methodology/approach The analysis of the geometric accuracy of the blades was performed using non-contact optical coordinate scanner ATOS Triple Scan II Blue Light, manufactured by GOM Company, at the Department of Mechanical Engineering, Rzeszów University of Technology. Geometric analysis was conducted for blades manufactured from different waxes (A7Fr/60 and RealWax VisiJet CPX200), thus comparing injection technique and rapid prototyping (RP) method, and for casting made of Inconel 713C nickel-based superalloy. Findings The analysis of the criteria for the method of blades’ measuring selection showed that the chosen system successfully met all criteria for the verification of blades’ geometry at the selected stages of the process. ATOS II optical scanner with blue light technology allows measurement almost regardless of daylight or artificial (white) light. This allows the application of the measurement system in the production cycle, thus eliminating the need to create special conditions for measurements. Practical implications Requirements related to the accuracy of measured values, diversity and allowable measurement time are linked with the methods of production. Modern manufacturing methods based on computer-aided design systems/manufacturing/engineering systems require a non-contact optical measurement method based on the computer-aided-based coordinate measuring technique. In case of the non-contact optical scanning method based on the ATOS GOM measuring system, time and measurement costs depend on the methodology of measurement and the possibility of its automation. This is why the presented paper has a practical impact on possibilities for the automation of geometric accuracy measurements of obtained elements in the series production line. Social implications The use of ATOS Triple Scan II Blue Light by GOM Company allows the reduction of cost and time of production because of the possibility of the introduction of this system in an automated production line. Additionally, the measurement of hot section blades of aircraft engines by using the blue light method is much more accurate and has implication as it impacts safety of further used manufactured elements. Originality/value This paper presents the possibility of using the ATOS Triple Scan II Blue Light measuring system for geometric accuracy measurements in case of hot section blades of aircraft engines. This research is original because it describes three model geometric accuracy measurements, wax model obtained using the injection technique, wax model obtained using the I RP process and casting made of Inco...

This article presents a procedure for minimizing ATOS II Triple Scan system measurement errors during the verification of geometrical accuracy of the final lateral-mandibular condyle model. The process of manufacturing a template geometrically similar to that of lateral-mandibular condyle was performed on the five-axis machining centre 100 DMU MonoBlock. The next stage of the research was related to the implementation of the measurement system procedure on the template model, and the 12 anatomical models of the mandibular body-condyle were manufactured using five different additive methods. As a result of the comparison of anatomical models of the mandibular body-condyle designed in reverse engineering/computer-aided design systems and manufactured using additive methods, the average results of histograms and parameters determining the accuracy of geometry of 12 models were obtained. In the case of models manufactured using fused deposition modelling, PolyJet and selective laser sintering techniques, a unimodal distribution was observed in the same way as in the template model. The best results were obtained in the case of models manufactured using selective laser sintering techniques (standard deviation = 0.06 mm). In the case of fused deposition modelling and PolyJet, a similar value of standard deviation (about 0.07 mm) was observed, despite the fact that the layer thickness for PolyJet technology was 0.016 mm. In the case of melted and extruded modelling and ColorJet Printing technologies, there was a bimodal distribution. Through the implementation of own template and measurement method, it will be easier to estimate errors in the manufacturing of anatomical models of lateral-mandibular condyle part. As a result, medical models, surgical templates and implants will be manufactured more accurately and precisely, which will significantly reduce intraoperative complications during the surgical procedure in this area.

Technological process of aircraft engine turbine blades requires control of blade geometric parameters. Innovation technologies for measurement of aircraft engine turbine blades are based on coordinate numerical machines-measurement process is based on processing of numerical data obtained by measurement using coordinate measuring machines. The paper presents the opportunity of analysis of dimensional accuracy of aircraft engine turbine blades measurements using coordinate measuring machine (CMM). Coordinate measuring machine allows specifying full methodology for designation of complex dimensions of physical objects (blade of aircraft engine) and transforming them into a computer program space of coordinate measuring devices. Presented paper includes capabilities of device used in the study to improve the measurement process and blades geometry analysis in the technological and economical aspects. Another issue described in the paper is impact of measurement performance in automatic mode on the quality of performance-the numerical model of geometry, from the standpoint of accuracy and number of collected data points in time. Measurements using a coordinate measuring machine are among the most accurate methods of measuring. The paper includes an analysis of conditions related to the measurement works, such as the process of preparing the model, measurement equipment and data processing capacity. As the result, methodology of (CMM) measurements of aircraft engine turbine blades will be presented.

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