Int. J. of Mechatronics and Manufacturing Systems   »   2016 Vol.9, No.4

 

 

Title: Optimised methodology for aircraft engine IBRs five-axis machining process

 

Authors: Egoitz Artetxe; Haizea González; Amaia Calleja; Asier Fernández Valdivielso; Roberto Polvorosa; Aitzol Lamikiz; L. Norberto López De Lacalle

 

Addresses:
Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain
Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain
Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain
Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain
Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain
Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain
Department of Mechanical Engineering, Faculty of Engineering of Bilbao, University of the Basque Country, Bilbao 48013, Spain

 

Abstract: Integral bladed rotors (IBRs), such as impeller and blisk, have become five-axis machining reference components. Due to its functional and technical requirements, these parts consist of complex geometry and are manufactured in difficult to cut materials. Despite the recent advances in five-axis machining, these components manufacturing is still a challenge. In the present work a methodology for a reliable machining process of IBRs is proposed. Geometric and process simulations were added to the initial toolpath design process in order to improve obtained part quality. A machine kinematics simulation allowed optimising machining set up. In addition, a mechanical analysis was developed to simulate the cutting forces. Several impeller and blisk geometries were milled to validate and optimise the process.

 

Keywords: IBR; integral bladed rotors; impellers; blisks; five-axis machining; toolpath design; axial compressors; centrifugal compressors; cutting force; flank milling; point milling; optimisation; aircraft engines; aero engines; component manufacturing; simulation; machine kinematics.

 

DOI: 10.1504/IJMMS.2016.10003806

 

Int. J. of Mechatronics and Manufacturing Systems, 2016 Vol.9, No.4, pp.385 - 401

 

Date of acceptance: 29 Jul 2016
Available online: 10 Mar 2017

 

 

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