Title: Efficient machining of aero-engine components: challenges and outlook

Authors: Harry Bikas; Panagiotis Stavropoulos; George Chryssolouris

Addresses: Laboratory for Manufacturing Systems and Automation, Department of Mechanical Engineering and Aeronautics, University of Patras, 26500 Patras, Greece ' Laboratory for Manufacturing Systems and Automation, Department of Mechanical Engineering and Aeronautics, University of Patras, 26500 Patras, Greece; Department of Aeronautical Studies, Hellenic Air Force Academy, Dekelia Air-Force Base, TGA 1010 Athens, Greece ' Laboratory for Manufacturing Systems and Automation, Department of Mechanical Engineering and Aeronautics, University of Patras, 26500 Patras, Greece

Abstract: Increasing the efficiency of gas turbines relies heavily upon machining of Ni-based superalloys. New alloys are continuously being created with increased operating temperature range, which in turn increases the gas turbine efficiency. However, these new-age superalloys are extremely difficult to machine, making production expensive and inefficient. In the present work, challenges regarding machining of such alloys are identified and an outlook on promising future developments is being given. Challenges are being categorised in four main pillars, namely simulation tools, monitoring systems, cutting tools and non-conventional machining strategies, which together with the machine tool form the complete machining environment. State-of-art in the respective fields is discussed, followed by a discussion of works with potential for significant improvements in the field of Ni-based superalloys machining.

Keywords: milling; process simulation; cutting tools; machining strategies; process monitoring; aero engine components; component machining; aircraft engines; aero engines; gas turbines; nickel superalloys; non-conventional machining.

DOI: 10.1504/IJMMS.2016.082871

International Journal of Mechatronics and Manufacturing Systems, 2016 Vol.9 No.4, pp.345 - 369

Received: 31 Oct 2015
Accepted: 29 Jul 2016
Published online: 14 Mar 2017 *

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