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In order to improve machining efficiency and quality of aero-engine blisks, a novel multi-spindle 5-axis machine tool is developed under the inspiration of the blisk structure. The proposed machine contains 8 spindles, which are arranged radially along the blisk and simultaneously participate in machining. The actuator of the machine contains three rotation axes and two translation axes, which can realize 5-axis CNC machining. Based on the unified kinematics model, the mechanism is analyzed in terms of forward and inverse kinematics, singularity, and flexible workspace. Meanwhile, the structural parameters of the machine are optimized according to the flexibility index to improve the kinematic performance of the mechanism. Theoretical and experimental results show that the machine tool has a more compact structure, fewer moving axes, and better kinematics performance, compared with the traditional multi-spindle modular machine tool. Therefore, the machine has significant advantages in processing efficiency and has great application potential in large batch machining of the blisk. [ABSTRACT FROM AUTHOR]

Blade is the core component of aero-engine, and its manufacturing capability improvement has always been the focus of aviation manufacturing industry. With the high-efficiency machining of multi-spindle machine tool, this paper proposes a synchronous polishing method based on the cluster grouping of actual blade profile. Firstly, the multi-spindle machining system, flexible polishing with determined path, and synchronous polishing process cycle are analyzed in detail. Secondly, the allowable difference within group is determined by the relationship of polishing compression and surface roughness/removal. Then, the distribution of grouping mark points is determined by the profile differences of sampled blades. Thirdly, the consistency of each two blade profiles is expressed as the vector difference of measurement data, and the grouping result can be established with the Ray-Turi index. Finally, a typical blade is used to demonstrate the effectiveness and efficiency. After multi-spindle synchronous polishing, the average synchronous polishing cycle time is 3.14 times less than single-spindle machine tool, the profile error and its difference are less than 0.0685 mm and 0.048 mm, the surface roughness can satisfy Ra ≤ 0.4 μ m , which can meet the design requirement of aero-engine blade. [ABSTRACT FROM AUTHOR]

The aero-engine blade is typically a thin-walled part with poor rigidity and a complex structure. This causes aero-engine blades to be susceptible to flutter and deformation during the machining processing, leading to the dimensional and positional accuracy outside the stipulated tolerance values. With the aim of improving the machining precision of the blades, the conventional blade processing methods were analysed in this study. Based on the analysis, a novel deformation control method named reverse segment machining method was proposed. Additionally, a stress-free auxiliary fixture was designed to improve the stiffness of thin-walled parts. Finally, an experiment was conducted to study the effectiveness of the developed reverse segment method and the stress-free auxiliary fixture in comparison to the forward machining methods. The results show that they can significantly improve machining precision. [ABSTRACT FROM AUTHOR]

Contact calculation is of great importance in predicting the material removal (MR) of flexible grinding process (FGP). The contact is mostly considered approximately constant in the existing MR models, while the situations that contact varies a lot after FGP are ignored. Therefore, a novel model is proposed in this paper to take those situations into consideration. Firstly, the nonconstant-contact situation is introduced. Then, an equivalent method is developed to convert the nonconstant-contact grinding process into the accumulation of several quasi-constant-contact grinding processes. Based on the equivalent method, a MR model is established, and the procedure to obtain the model parameters by the finite element analysis (FEA) is introduced. In the end, the equivalent method and the MR model are tested by a series experiments of different process parameters. Results show that the proposed MR model can predict the material removal effectively for the nonconstant-contact situations. [ABSTRACT FROM AUTHOR]

The sculptured surface has been widely used in aerospace and machinery manufacturing industries. CNC machining of sculptured surfaces is an important research area, and computation efficiency improvements are considered critical topics in this field. This paper presents a highly efficient method to generate smooth tool paths by establishing a mathematical model to describe the relationship between the relative curvature of sculptured surface and the machining strip width in five-axis machining. The method is improved from the middle-point error control method (MPECM) and the feasible tool position surface method (FTPSM), by changing the objective from the complete optimization for each drive point to the drive points' interpolation. The drive point with the narrowest machining strip width and some sample points is selected to interpolate the remaining points. Both theoretical analysis and test examples show the correctness of the proposed method. Under the same condition, compared with the MPECM and the FTPSM, the computing time of the new method decreases to 10% at least. Besides, the fluctuation of the tool path is reduced. The machining examples verified the superiority of the proposed method. [ABSTRACT FROM AUTHOR]

As a result of the recently increasing demands on high-performance machining technology in the aero-engine industry, the near-net shape forming technique can be suitable for many integrated impellers. However, the previous forming deformation can raise serious problems for the secondary NC machining of non-formed area, which is mostly applicable for leading/trailing edge (LE/TE) and its adjacent area. It is even worse that non-designed shape and dimension of LE/TE may be responsible for the deteriorated aerodynamic performance and subsequent high in-service cost, especially when its radius is small. Based on previous efforts, this paper presents a 5-axis adaptive machining framework for the LE/TE of near-net-shape integrated impeller. On-machine measurement (OMM) with a touch-trigger probe is utilized to digitalize the impeller. The distribution and uncertainty of sampling points are taken into account with data processing. Through the comparison between the measured and nominal geometric parameters, the impeller profile can be reconstructed sequentially on each tandem cascade. Among this, the camber line deformation emphasizes the functional significance of design intent and the thickness distribution conforms the processed data at most degree. Utilizing the ability to remove small allowance and the low continuous grinding force, the 5-axis CNC grinding with electroplated cubic boron nitride (CBN) wheel is carried out. Moreover, typical examples are used to demonstrate the effectiveness and superiority of this strategy. [ABSTRACT FROM AUTHOR]

In five-axis machining, multipoint tool orientation has the merit of getting a wider strip width. However, large computing time restricts its application. In this paper, for machining free-form surfaces by toroidal tools, a highly efficient and convergent multipoint tool orientation optimization method is proposed. The method is improved from Middle Point Error Control Method (MPECM), by changing the objective from the maximum strip width to multipoint tool orientation. H-function is defined, and the consistency between multipoint tool orientation and H-function's zero is demonstrated. Based on that, the seeking for optimal tool orientation is equivalent to the computation of H-function's zero. Under the same conditions, compared with MPECM and mechanical equilibrium method (MEM), the computing time of the proposed method decreases to 5% at least. Convergence is ensured by the analysis of the existence of multipoint tool orientation. In the end, the proposed method is validated in machining a mold surface and an aero-engine blade. [ABSTRACT FROM AUTHOR]

Avoiding significant fluctuations of tool orientation is an important problem in five-axis machining. The dramatic change of tool orientation may greatly increase the angular acceleration of machine rotary axes, produce larger nonlinear machining errors and gouging, reduce the feed rate of machine rotary axes, etc. In this paper, we propose a tool orientation smoothing method based on machine rotary axes for five-axis machining with ball end cutters to reduce fluctuations of tool orientation in the machine coordinate system (MCS). The core idea of the proposed method is to directly smooth machine rotary angles in the machine coordinate system for the smooth variation of tool orientation. First of all, we establish the relationship between the design variables of tool position and machine rotary angles. Then, we define an objective function of tool orientation smoothing based on machine rotary angles. In order to solve the above objective function, we also develop a simplified algorithm to obtain the minimum sum of squares of compound angular accelerations. Finally, a blade surface is used as a test example, and tool paths are generated by the Sturz and proposed methods, respectively. Comparison and analysis results show that the proposed method can improve the kinematics performance of five-axis machine tool, as well as surface machining quality and efficiency. [ABSTRACT FROM AUTHOR]

The cutter posture optimization in five-axis machining is of importance for machining efficiency and quality. In order to achieve a cutter posture with wide strip width, this paper proposes a mechanical equilibrium-based method. When the defined middle point on the cutter is fixed, two contact points are needed and obtained for seeking an equilibrium state of the cutter. After initially positioned on the desired surface, the cutter is firstly stressed by the gravity, then impact on the desired surface. The process repeats until the cutter is in an equilibrium state. The uplift of the cutter is also optimized to avoid excess that caused by the shift of the actual middle point on the error distribution curve. In the implementation, the proposed method distinctly increases the strip width compared with two existing methods. [ABSTRACT FROM AUTHOR]

This paper presents a method to reduce the fluctuation of machining strip width by modifying tool position. When the machining strip width varies rapidly within a tool path, the fluctuation of cutting force brings negative influence on the workpiece and cutter. Furthermore, as the tool path interval is always defined conservatively to avoid undercut, the machined strips of adjacent tool paths have unnecessary amount of overlap. Rapid changing machining strip width usually creates too much overlap at some location, which causes repeated cutting. A method is proposed to modify tool position and reduce the fluctuation of machining strip width. Besides, tilt angle smoothness along the tool path is also taken into account. The computation result of a blade surface verified the validity of the proposed method. [ABSTRACT FROM AUTHOR]

The multi-point tool positioning algorithms produce much larger machining strip width than the single-point algorithms and apparently reduce the actual machining time. This paper presents a tool positioning algorithm for multi-point machining of sculptured surface, which is excellent at dealing with both of concave and convex surfaces. The proposed method is based on the middle-point error control (MPEC) method, which means the connection point between cutter and surface corresponds to the middle point of error distribution curve. Usually, only one cut contact (CC) point can be obtained with this method. Thus, the proposed method improved the MPEC method for achieving two CC points. At first, the shape of error distribution curve is investigated, and its asymmetry is evaluated. Secondly, the error distribution curve becomes symmetrical after the cutter is rotated with a roll angle, and the cutter is separated with surface at the same time. Finally, the minimum tilt angle is found, and two CC points are obtained without gouging. Machining experiment is conducted to verify the proposed method, and the result reveals that the machining strip width is increased apparently and the tool position is almost unchanged after the adjustment with proposed method. Simulation, measurement, and analysis are also given in the part of the experiment. [ABSTRACT FROM AUTHOR]