Compensation of part distortion in process design for re-contouring processes

The repair of compressor blades requires a precise coordination of the material deposit and the subsequent re-contouring process. Since re-contouring is the last step in the process chain, it is a crucial stage for the final part quality and shape. Therefore, machining-induced part distortions must be considered in process design. This paper introduces a method for the simulation-based compensation of part distortions. The method combines process planning and evaluation by means of a geometric simulation. In order to validate the approach, milling experiments are carried out. A subsequent measurement of the part geometry shows that the part distortion can be reduced by up to 21% using the presented approach. © 2019 The Authors. Published by Elsevier Ltd

Adaptive location of repaired blade for multi-axis milling

Free-form blades are widely used in different industries, such as aero-engine and steam turbine. Blades that are damaged during service or have production deficiencies are usually replaced with new ones. This leads to the waste of expensive material and is not sustainable. However, material and costs can be saved by repairing of locally damaged blades or blades with localized production deficiencies. The blade needs to be further machined after welding process to reach the aerodynamic performance requirements. This paper outlines an adaptive location approach of repaired blade for model reconstruction and NC machining. Firstly, a mathematical model is established to describe the localization problem under constraints. Secondly, by solving the mathematical model, localization of repaired blade for NC machining can be obtained. Furthermore, a more flexible method based on the proposed mathematical model and the continuity of the deformation process is developed to realize a better localization. Thirdly, by rebuilding the model of the repaired blade and extracting repair error, optimized tool paths for NC machining is generated adaptively for each individual part. Finally, three examples are given to validate the proposed method