An investigation on adaptively machining the leading and tailing edges of an SPF/DB titanium hollow blade using free-form deformation |
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Authors: | Zhengcai ZHAO Jiuhua XU Yucan FU Zhiqiang LI |
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Institution: | 1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China;2. Beijing Aeronautics Manufacturing Technology Research Institute, Beijing 100024, China |
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Abstract: | Titanium hollow blades are characterized with lightweight and high structural strength, which are widely used in advanced aircraft engines nowadays. Superplastic forming/diffusion bonding (SPF/DB) combined with numerical control (NC) milling is a major solution for manufacturing titanium hollow blades. Due to the shape deviation caused by multiple heat and pressure cycles in the SPF/DB process, it is hard to manufacture the leading and tailing edges by the milling process. This paper presents a new adaptive machining approach using free-form deformation to solve this problem. The actual SPF/DB shape of a hollow blade was firstly inspected by an on-machine measurement method. The measured point data were matched to the nominal SPF/DB shape with an improved ICP algorithm afterwards, by which the point-pairs between the measurement points and their corresponding points on the nominal SPF/DB shape were established, and the maximum modification amount of the final nominal shape was constrained. Based on the displacements between the point-pairs, an accurate FFD volume was iteratively calculated. By embedding the final nominal shape in the deformation space, a new final shape of the hollow blade was built. Finally, a series of measurement and machining tests was performed, the results of which validated the feasibility of the proposed adaptive machining approach. |
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Keywords: | Adaptive machining Blade geometry Free-form deformation Reconstruction Titanium |
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