Constructing Process Models of Engine Blade Surfaces for Their Adaptive Machining: An Optimal Approach

2018 ◽  
Vol 141 (1) ◽  
Author(s):  
Neng Wan ◽  
Peng Liu ◽  
Zezhong C. Chen ◽  
Zhiyong Chang
Keyword(s):  
Manufacturing Process ◽  
Process Models ◽  
Tool Paths ◽  
Design Tolerance ◽  
Adaptive Machining ◽  
Trailing Edges ◽  
Engine Blade ◽  
Blade Machining ◽  
Blade Edge ◽  
Optimal Approach

In a new blade manufacturing process, manufacturers precisely forge blade billets with the blade suction and the pressure surfaces within tolerance. After that, only two blade edge billets should be machined to the leading- and the trailing-edges within tolerance. If these edge design surfaces are used to generate tool paths for machining the edge billets, the machined edges are not continuous with the suction and the pressure surfaces. To address this problem, an optimal approach to constructing process models of edge surfaces is proposed for adaptive blade machining. Specifically, the modified edge surfaces are optimized within the design tolerance and are continuous with the billet suction and pressure surfaces. These surfaces are used to generate tool paths for machining the edge billets. This approach addresses the current technical challenge in the new blade manufacturing process and can substantially promote this process in blade mass production.

Toward Metamodels for Composable and Reusable Additive Manufacturing Process Models

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Paul Witherell ◽  
Shaw Feng ◽  
Timothy W. Simpson ◽  
David B. Saint John ◽  
Pan Michaleris ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Metal Powder ◽  
Manufacturing Process ◽  
Process Model ◽  
Model Development ◽  
Process Models ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Future Work ◽  
Am Processes

In this paper, we advocate for a more harmonized approach to model development for additive manufacturing (AM) processes, through classification and metamodeling that will support AM process model composability, reusability, and integration. We review several types of AM process models and use the direct metal powder bed fusion AM process to provide illustrative examples of the proposed classification and metamodel approach. We describe how a coordinated approach can be used to extend modeling capabilities by promoting model composability. As part of future work, a framework is envisioned to realize a more coherent strategy for model development and deployment.

Optimal Rough Machining of Sculptured Parts on a CNC Milling Machine

1993 ◽  
Vol 115 (4) ◽  
pp. 424-431 ◽  
Author(s):  
Z. Dong ◽  
H. Li ◽  
G. W. Vickers
Keyword(s):  
Production Costs ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Rough Machining ◽  
Machining Time ◽  
Tool Paths ◽  
Cnc Milling Machine ◽  
Cnc Programming ◽  
Sculptured Parts ◽  
Optimal Approach

An optimal approach to the rough machining of sculptured parts with least machining time is presented. The contour map cutting method is used to generate CNC tool paths based on the CAD model of sculptured parts. The part and stock geometry related parameters, including the number of cutting layers and the distributions of cutting depth, and the process parameters of feed rate and depth of cut, are optimized. The method can automate CNC programming for sculptured part rough machining, considerably improve productivity, and lower production costs. Two examples are used to illustrate the approach and its advantages.

scholarly journals Investigations on Temperature Fields during Laser Beam Melting by Means of Process Monitoring and Multiscale Process Modelling

2014 ◽  
Vol 6 ◽  
pp. 217584 ◽  
Author(s):  
J. Schilp ◽  
C. Seidel ◽  
H. Krauss ◽  
J. Weirather
Keyword(s):  
Process Monitoring ◽  
Manufacturing Process ◽  
Computation Time ◽  
Simulation Models ◽  
Process Models ◽  
Temperature Fields ◽  
Transient Temperature ◽  
Transient Temperature Field ◽  
Laser Beam Melting ◽  
Simulation Based

Process monitoring and modelling can contribute to fostering the industrial relevance of additive manufacturing. Process related temperature gradients and thermal inhomogeneities cause residual stresses, and distortions and influence the microstructure. Variations in wall thickness can cause heat accumulations. These occur predominantly in filigree part areas and can be detected by utilizing off-axis thermographic monitoring during the manufacturing process. In addition, numerical simulation models on the scale of whole parts can enable an analysis of temperature fields upstream to the build process. In a microscale domain, modelling of several exposed single hatches allows temperature investigations at a high spatial and temporal resolution. Within this paper, FEM-based micro- and macroscale modelling approaches as well as an experimental setup for thermographic monitoring are introduced. By discussing and comparing experimental data with simulation results in terms of temperature distributions both the potential of numerical approaches and the complexity of determining suitable computation time efficient process models are demonstrated. This paper contributes to the vision of adjusting the transient temperature field during manufacturing in order to improve the resulting part's quality by simulation based process design upstream to the build process and the inline process monitoring.

Path Planning for Circular Cutter Envelop Milling of Steam Turbine Blade

2014 ◽  
Vol 989-994 ◽  
pp. 2908-2912
Author(s):  
Jian Jun Wang ◽  
Ke Wang ◽  
Qiong Wu
Keyword(s):  
Steam Turbine ◽  
Turbine Blade ◽  
Tool Path ◽  
Vertical Section ◽  
Surface Matching ◽  
Nurbs Surface ◽  
Processing Efficiency ◽  
Tool Paths ◽  
Blade Machining ◽  
Steam Turbine Blade

In order to solve the problem of poor steam turbine blade processing efficiency, and on the basis of analyzing the turbine blade surface and the existing processing methods, a model of circular cutter turbine blade machining is built. By comparing the tool paths of horizontal and vertical section envelope machining, choosing quasi-vertical cross section envelope machining method and utilizing the original datum and NURBS surface matching mathematic methods, this paper provides an algorithm of residual height calculating, and based on this, the tool path can be planned. Datum show that, the tool path of circular cutter machining blades is much longer than the tool path of ball-end cutter envelop milling machining blades, and the machining efficiency is also highly enhanced.

Research on the Key Technology of NC Abrasive Belt Grinding for the Leading and Trailing Edges of Aeroengine Blades

2012 ◽  
Vol 565 ◽  
pp. 76-81 ◽  
Author(s):  
Yun Huang ◽  
Xiao Xiao Ye ◽  
Ming De Zhang ◽  
Hong Wen Fang
Keyword(s):  
Control Method ◽  
Dimensional Accuracy ◽  
Pressure Control ◽  
Grinding Process ◽  
Belt Grinding ◽  
Key Technology ◽  
Abrasive Belt ◽  
Model Research ◽  
Trailing Edges ◽  
Blade Machining

This document provides an analysis of the structure characteristics and grinding process requirements of leading and trailing edges, and proposes a grinding process of leading and trailing edges, established a uneven grinding margin model, research the quantitative grinding pressure control method of uneven margin, as well as the error compensation technology of blade machining deformation, and experiments were carried out on the basis of theories above. The experimental results demonstrate that: after grinding, the edge roundness improved greatly, dimensional accuracy of edge radius can reach ±0.07mm.Compared with the traditional manual polishing method, the grinding quality improved significantly.

An Agent Based Optimization Approach to Manufacturing Process Planning

2001 ◽  
Author(s):  
Saurabh Deshpande ◽  
Jonathan Cagan
Keyword(s):  
Stochastic Optimization ◽  
Process Planning ◽  
Manufacturing Process ◽  
Optimization Problems ◽  
Search Space ◽  
Optimization Techniques ◽  
Process Models ◽  
Optimization Approach ◽  
Agent Based ◽  
Manufacturing Process Planning

Abstract Many optimization problems, such as manufacturing process planning optimization, are difficult problems due to the large number of potential configurations (process sequences) and associated (process) parameters. In addition, the search space is highly discontinuous and multi-modal. This paper introduces an agent based optimization algorithm that combines stochastic optimization techniques with knowledge based search. The motivation is that such a merging takes advantage of the benefits of stochastic optimization and accelerates the search process using domain knowledge. The result of applying this algorithm to computerized manufacturing process models is presented.

Towards a Standards-Based Methodology for Extending Manufacturing Process Models for Sustainability Assessment

2018 ◽  
Author(s):  
Arvind Shankar Raman ◽  
Karl R. Haapala ◽  
K. C. Morris
Keyword(s):  
Manufacturing Process ◽  
Sustainability Assessment ◽  
Building Blocks ◽  
Cnc Machining ◽  
Process Models ◽  
Machining Processes ◽  
Complex Processes ◽  
Information Models ◽  
Computer Numerically Controlled ◽  
Application Specific

Over the past decade, several efforts have characterized manufacturing processes from a sustainability perspective. In addition, frameworks, methodologies, and standards development for characterizing and linking unit manufacturing process (UMP) models to construct manufacturing system models for supporting sustainability assessment have been pursued. In this paper these research efforts are first briefly reviewed, and then, ASTM standards derived from this work are described and built upon. The contribution of this research is to demonstrate how more formalization of these prior efforts will facilitate systematic reuse of developed models by encapsulating different aspects of complex processes into reusable building blocks. The research proposes a methodology to define template UMP information models, which can further be abstracted and customized to represent an application-specific, upgraded manufacturing process. The methodology developed is based on the ASTM standards of characterizing manufacturing process for sustainability characterization. The approach is demonstrated for analyzing manual and computer numerically controlled (CNC) machining processes.

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