首页|Efficient machining of a complex blisk channel using a disc cutter

Efficient machining of a complex blisk channel using a disc cutter

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For rough machining of a complex narrow cavity,e.g.,a complex blisk channel on an aero-engine,the typically used cutting tools are the slender cylindrical cutter and conical cutter.Nevertheless,as neither of the two is particularly suited for rough machining,wherein the main pur-pose is to remove a large volume as quickly as possible,the machining efficiency is low,especially when the part materials are of hard-to-cut types(e.g.,Titanium-alloy)for which it often takes days to rough machine a blisk.Fortunately,disc machining provides a new and efficient roughing solu-tion,since a disc cutter with a large radius enables a much larger cutting speed and thus a larger material removal rate.However,due to the large radius of the disc cutter,its potential collision with narrow and twisted channels becomes a serious concern.In this paper,we propose a novel two-phase approach for efficiently machining a complex narrow cavity workpiece using a disc-shaped cutter,i.e.,3+2-axis disc-slotting of the channel by multiple layers(rough machining)+five-axis disc-milling of the freeform channel side surfaces(semi-finish machining).Both simulation and physical cutting experiments are conducted to assess the effectiveness and advantages of the pro-posed method.The experimental results show that,with respect to a same cusp-height threshold on the channel side surfaces,the total machining time of the tested part by the proposed method is about only 36％of that by the conventional approach of plunging-milling(for roughing)plus milling by a slender cylindrical cutter(for semi-finishing).

Blisk channelCNC machiningDisc cutterRoughing efficiencyTool path planning

Xiangyu LI、Zhaoyu LI、Dong HE、Junxue REN、Qian FENG、Kai TANG

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Department of Mechanical and Aerospace Engineering,Hong Kong University of Science and Technology,Hong Kong 999077,China

Key Laboratory of High Performance Manufacturing for Aero Engine(Northwestern Polytechnical University),Ministry of Industry and Information Technology,Xi'an 710072,China

Xi'an Sanhang Power Technology Co.,Ltd,Xi'an 710000,China

HKUST Shenzhen-Hong Kong Collaborative Innovation Research Institute,Futian,Shenzhen 518057,China

HKUST Shenzhen Research Institute,Shenzhen 518057,China

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Foshan HKUST ProjectsProject of Hetao Shenzhen-Hong Kong Science and Technology Innovation Cooperation ZoneNational Science and Technology Major Project

FSUST20-SRI09E-FSPM02202007-1HZQB-KCZYB-2020083J2019-Ⅶ-0001-0141

2024

10.1016/j.cja.2023.04.017

中国航空学报(英文版)
中国航空学会

中国航空学报(英文版)

CSTPCDEI
影响因子：0.847
ISSN：1000-9361
年,卷(期)：2024.37(1)
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