Dressing process in the grinding of aerospace blade root

This review article presents a summary of currently used and proposed methods of manufacturing fir tree slots of discs in turbine engines. The production of aircraft, including aircraft engines during times of overlapping global economic crises related to the COVID-19 pandemic or the war in Eastern Europe requires a quick response to the changing numbers of passengers and cargo. Similarly, the aviation industry must adapt to these conditions, and thus utilize flexible production methods allowing for a quick change in the design or type of a given part. Due to the constant adoption of new materials for the most critical aero engine parts and the necessity of complying with environmental regulations, it is necessary to search for new methods of manufacturing these parts, including fir tree slots. As an alternative to currently used expensive and energy-intensive broaching, many manufacturers try to implement creep feed grinding CFG or contour milling. However, other manufacturing methods, thus far rarely used for crucial machine parts such as WEDM, ECDM or AWJ, are gaining more and more popularity in the aviation industry. This article presents the advantages and shortcomings of these methods in the context of manufacturing fir tree slots.

show abstract

Section: Methods Of Manufacturing Fir Tree Slots Of the Turbine Discsmentioning

confidence: 99%

“…It can be divided into grinding with cup-grinding wheels or pin-grinding wheels. Grinding with cup wheels (Figure 21) applies only to the finishing machining of large-sized slots [36,72]. A more comprehensive solution was proposed by Aspinwall et al It i ing with pin wheels with diamond (D46) and cBN (B46, B76, B91) coatings ( 75].…”

Section: Grindingmentioning

confidence: 99%

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

2023

View full text Add to dashboard Cite

show abstract

“…The first one is the creep feed grinding (CFG), in which a highly porous, conventional grinding wheel machines the workpiece with very high depths of cut (in some cases, up to even 20 mm) and low feed rates. The process is used in the aerospace and automotive industry in machining difficult-to-cut materials such as superalloys and refers mainly to surface grinding, although can also be used in cylindrical grinding [6,7]. The second one-pass method -known as traverse contour grinding or continuous path-controlled grinding (CPCG) -is recognised as an alternative to hard turning and consists of using a narrow cylindrical grinding wheel (cBN), which follows the shape of the workpiece [8][9][10].…”

Section: Introductionmentioning

confidence: 99%

A Method of Increasing the Accuracy of Low-Stiffness Shafts: Single-Pass Traverse Grinding Without Steady Rests

Sułkowicz

Babiarz

Burek

et al. 2022

Acta Mechanica Et Automatica

Self Cite

View full text Add to dashboard Cite

The article presents a method of increasing the shape and dimensional accuracy of low-stiffness shafts manufactured in a single pass of a grinding wheel in traverse grinding. One-pass manufacturing is one of the ways for reducing machining time and increasing efficiency, thus lowering production costs. However, maintaining the necessary accuracy proves to be a challenge because the whole machining allowance has to be removed at once, leaving no room for errors that could be fixed in additional passes of the tool. It is especially true in finishing operations, such as traverse grinding. In addition, grinding the workpiece in a single pass of a grinding wheel leads to high forces, which cause elastic deformation of the part. The lower the stiffness of the part, the more difficult it is to achieve the required accuracy. As a result, there are many methods of improving the accuracy of grinding such parts, but they tend to be either expensive or reduce the machining efficiency. Thus, it is important to seek new methods that would allow improving the accuracy of the machining without reducing its efficiency. The proposed method does not require using steady rests and is based on the measurement of the normal grinding force component. Knowing the value of the grinding force when grinding with a set grinding depth, the elastic deformation of the machine tool–tool–workpiece system is calculated in each position of the grinding wheel. Based on the calculated deformation, the additional infeed of the grinding wheel is implemented in order to stabilise real grinding depth and to increase the accuracy of the produced part. The experimental tests were conducted to prove the effectiveness of the proposed method.

show abstract

Experimental studies using minimum quantity cooling (MQC) with molybdenum disulfide and graphite-based microfluids in grinding of Inconel® alloy 718

Wojtewicz

Nadolny

Kapłonek

et al. 2018

Int J Adv Manuf Technol

View full text Add to dashboard Cite

In the paper, the results of experimental studies related with determination of the influence of the supply of a grinding fluid (GF) doped with powdered graphite and MoS 2 into the machining zone with the minimum quantity cooling (MQC) method on the course and results of the reciprocating internal cylindrical grinding of rings made from Inconel® alloy 718 have been presented. As a grinding fluid, water aerosols were used. The aerosols delivered the following into the grinding zone: water slurry MoS 2 with a concentration of 30 g/dm 3 , water slurry of graphite with a concentration of 30 g/dm 3 , 5% water solution of Syntilo RHS oil and pure demineralized water. The obtained results of carried out experiments showed that the most favorable conditions of grinding wheel operation were obtained when MQC-based delivering an aerosol of water slurry made from demineralized water doped with MoS 2 and graphite with a minimum flow rate and when delivering an aerosol of 5% water slurry of Syntilo RHS oil. It was proved that doping GF with powdered MoS 2 and graphite, with delivery in the form of an aerosol with a minimum flow rate, has a substantial influence on the intensity of clogging grinding wheel active surface (GWAS). Additionally, it has been demonstrated that the solid grease MoS 2 and graphite particles reached the area of contact of the GWAS and the machined surface effectively, actively influencing its tribological conditions of the grinding process.

show abstract

Dressing process in the grinding of aerospace blade root

Cited by 7 publications

References 22 publications

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

A Method of Increasing the Accuracy of Low-Stiffness Shafts: Single-Pass Traverse Grinding Without Steady Rests

Experimental studies using minimum quantity cooling (MQC) with molybdenum disulfide and graphite-based microfluids in grinding of Inconel® alloy 718

Contact Info

Product

Resources

About