Blisk blades manufacturing technologies analysis

Ponencia presentada a 8th Manufacturing Engineering Society International Conference, MESIC 2019, 19-21 June 2019, Madrid, SpainThe paper presents blisk blades manufactured by different manufacturing processes. In this sense, different milling trajectories are presented, and, super abrasive machining strategies and EDM technologies are also tested. Machining times, costs and surface finish are analysed in order to determine optimal machining process for blisk manufactured in low machinability materials.The authors wish to acknowledge the financial support received from HAZITEK program, from the Department of Economic Development and Infrastructures of the Basque Government and from FEDER founds, related to the projects with acronym HARDCRAFT and TURALOY. Besides, thanks are also addressed to the Vice chancellor of innovation, social compromise and cultural action from UPV/EHU (Bizialab program from Basque Government) and to Spanish Project MINECO RTC-2017-6039-5

Blisk blades manufacturing technologies analysis

The paper presents blisk blades manufactured by different manufacturing processes. In this sense, different milling trajectories are presented, and, super abrasive machining strategies and EDM technologies are also tested. Machining times, costs and surface finish are analysed in order to determine optimal machining process for blisk manufactured in low machinability materials.RYC-2017-2264

On initialization of milling paths for 5-axis flank CNC machining of free-form surfaces with general milling tools

We propose a path-planning algorithm for 5-axis flank CNC machining with general tools of varying curvature. Our approach generalizes the initialization strategy introduced for conical tools [Bo et al., 2017] to arbitrary milling tools. Given a free-form (NURBS) surface and a rotational milling tool, we look for its motion in 3D to approximate the input reference surface within a given tolerance. We show that for a general shape of the milling tool, there exist locally and generically four 3D directions in which the point-surface distance follows the shape of the tool up to second order. These directions form a 3D multi-valued vector field and its integration gives rise to a set of integral curves. Among these integral curves, we seek straight line segments that correspond to good initial positions of the axes of the milling tool. We validate our method against synthetic examples with known exact solutions and, on industrial datasets, we detect approximate solutions that meet fine machining tolerances. We also demonstrate applicability of our method for efficient flank milling of convex regions that is not possible using traditional conical tools.RYC-2017-2264

Manufacturing Processes of Integral Blade Rotors for Turbomachinery, Processes and New Approaches

Manufacturing techniques applied to turbomachinery components represent a challenge in the aeronautical sector. These components are commonly composed of high resistant super-alloys; in order to satisfy the extreme working conditions, they have to support during their useful life. Besides, in the particular case of Integrally Bladed Rotors (IBR), they usually present complex geometries that need to be roughed and finished by milling and grinding processes, respectively. Thermoresistant superalloys present many challenges in terms of machinability what leads to find new alternatives to conventional manufacturing processes. In order to face this issue, this work presents a review of the last advances for IBR manufacturing and repairing processes.We are grateful to Basque Excellence university Groups IT IT1337-19, and Ministry of economy project IBRELIABLE (DPI2016-74845-R), and Elkartek PROCODA KK 2019-004