Reliable Manufacturing Process in Turbine Blisks and Compressors

Calleja, A.; Fernández, Ángel G.; Campa, Francisco J.; Lamíkiz, Aitzol; Lacalle, Luís Norberto López de

doi:10.1016/j.proeng.2013.08.214

Cited by 17 publications

(5 citation statements)

References 9 publications

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“…The continuous evolution of aviation engines requires the development of advanced materials and the improvement of manufacturing processes [1,2]. Nickel-based superalloys are widely used in aeroengine components, making up to about 50 wt % of the materials that are used for this application [3,4] due to their excellent mechanical properties at high temperatures and their resistance to corrosion [5].…”

Section: Introductionmentioning

confidence: 99%

Finishing Turning of Ni Superalloy Haynes 282

Díaz-Álvarez

Miguélez

et al. 2018

Metals

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Nickel-based superalloys are widely used in the aeronautical industry, especially in components requiring excellent corrosion resistance, enhanced thermal fatigue properties, and thermal stability. Haynes 282 is a nickel-based superalloy that was developed to improve the low weldability, formability, and creep strength of other γ’-strengthened Ni superalloys. Despite the industrial interest in Haynes 282, there is a lack of research that is focused on this alloy. Moreover, it is difficult to find studies dealing with the machinability of Haynes 282. Although Haynes 282 is considered an alloy with improved formability when compared with other nickel alloys, its machining performance should be analyzed. High pressure and temperature localized in the cutting zone, the abrasion generated by the hard carbides included in the material, and the tendency toward adhesion during machining are phenomena that generate extreme thermomechanical loading on the tool during the cutting process. Excessive wear results in reduced tool life, leading to frequent tool change, low productivity, and a high consumption of energy; consequentially, there are increased costs. With regard to tool materials, cemented carbide tools are widely used in different applications, and carbide is a recommended cutting material for turning Haynes 282, for both finishing and roughing operations. This work focuses on the finishing turning of Haynes 282 using coated carbide tools with conventional coolant. Machining forces, surface roughness, tool wear, and tool life were quantified for different cutting speeds and feeds.

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Section: Introductionmentioning

confidence: 99%

Finishing Turning of Ni Superalloy Haynes 282

Díaz-Álvarez

Miguélez

et al. 2018

Metals

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“…Industrial tests reveal a 70–80% reduction in NC programming time of parts with complex surfaces, and a reduced machining time of approximately 40–50% using basic high-speed cutting methods and custom-made tools. Calleja et al 9 consider the existing demand for better manufacturing technologies. A study case based on an Inconel 718 blisk finishing operations study is developed.…”

Section: Introductionmentioning

confidence: 99%

Improvement in the efficiency of the five-axis machining of aerospace blisks

et al. 2022

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Blisks are not easily machined because of their complex curved surfaces and the high-precision requirements of surface machining. Lightweight alloy materials with superior mechanical properties, such as titanium alloy and stainless steel, are popular material choices for manufacturing turbine blisks. However, these materials are difficult to cut and require advanced machine tools and processing technologies. Because aerospace-grade parts are complex and require precise dimensions and high surface quality, machining these parts by using three-axis machine tools is difficult. Using multi-axis machine tools for the machining of complex parts can cause the achievement of precise dimensions, high quality, and the required surface roughness. In the multi-axis machining of aerospace blisks, tool path planning is considered the most difficult task. In this study, we examined the implementation of five-axis machining technology for the manufacturing of an aerospace blisk. Processing modules from computer-aided manufacturing software (NX10) are used for five-axis tool path generating, and 5-axis machining numerical control code is generated through post-processing calculations. Solid cutting simulation software (VERICUT) is used to verify whether tools exhibited overcut or interference. A sensory tool holder (SPIKE) is used to analyze cutting force during the rough machining of a blisk. The sensory tool holder is also adopted to evaluate the spindle runout and tool holding status. In order to obtain a consistent cutting allowance and surface accuracy, the online measurement system is used to generate a measurement path for semi-finish and finish machining. The real cut is performed with SUS304 and demonstrates the practical application. Through improvements in process planning, the machining time was shortened by 16.5%.

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“…The blisk is a new-style key component of aero-engines, which rotor blade is integrated with the wheel disc. Compared to traditional blades and disk systems, the blisk has more advantages, including the lower weight, simple structure, higher reliability, long-service life and excellent reliability [1][2][3]. Therefore, the blisk has been widely utilized for modern high performance aero-engines.…”

Section: Introductionmentioning

confidence: 99%

Multi-Objective Parameter Optimization for Disc Milling Process of Titanium Alloy Blisk Channels

Shi

2019

Symmetry

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The blisk has been widely used in modern high performance aero-engines of high thrust-weight ratio. Disc milling process provides a reliable way to improve the efficiency of the blisk milling. The process parameters of disc milling have crucial effects on the milling efficiency and physical property of blisk. In this paper, material removal rate, cutter life and thickness of residual stress layer are regarded as optimization targets the key process parameters such as spindle speed, cutting depth and feed speed are optimized. Based on the grey relational analysis, the multi-objective optimization problem is transformed into a single objective optimization problem. At the same time, the problem of non-symmetry influence of key process parameters on optimization targets can be solved. And the influence weight of material removal rate, cutter life and thickness of residual stress layer on the grey relational grade (GRG) are calculated according to principal component analysis. The second order prediction model of GRA is developed by response surface method. On the basis of verifying the accuracy of the model, the influence mechanism of the process parameters coupling on the gray correlation degree is analyzed the optimal process parameter combination is obtained as spindle speed with 81.92 rpm, cutting depth with 5.88 mm and feed rate with 66.0823 mm/min. The experimental research show that the optimal process parameter combination can effectively improve the material removal rate and cutter life and reduce the thickness of residual stress layer.

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Reliable Manufacturing Process in Turbine Blisks and Compressors

Cited by 17 publications

References 9 publications

Finishing Turning of Ni Superalloy Haynes 282

Finishing Turning of Ni Superalloy Haynes 282

Improvement in the efficiency of the five-axis machining of aerospace blisks

Multi-Objective Parameter Optimization for Disc Milling Process of Titanium Alloy Blisk Channels

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