Cai Wentong, Liu Yue, Liu Zhanqiang, Cai Yukui, Wang Bing, Li Guoying
School of Mechanical Engineering, Shandong University, Jinan 250061, China.
Shenzhen Research Institute of Shandong University, A301 Virtual University Park in South District of Shenzhen, Shenzhen 518000, China.
Micromachines (Basel). 2021 Feb 26;12(3):237. doi: 10.3390/mi12030237.
Aero-engine blades are manufactured by electroforming process with electrodes. The blade electrode is usually machined with five-axis micromilling to get required profile roughness. Tool path planning parameters, such as cutting step and tool tilt angle, have a significant effect on the profile roughness of the micro-fillet of blade electrode. In this paper, the scallop height model of blade electrode micro-fillet processed by ball-end milling cutter was proposed. Effects of cutting step and tool tilt angle the machined micro-fillet profile roughness were predicted with the proposed scallop height model. The cutting step and tool tilt angle were then optimised to ensure the contour precision of the micro-fillet shape requirement. Finally, the tool path planning was generated and the machining strategy was validated through milling experiments. It was also found that the profile roughness was deteriorated due to size effect when the cutting step decreased to a certain value.
航空发动机叶片采用带电极的电铸工艺制造。叶片电极通常通过五轴微铣加工以获得所需的轮廓粗糙度。刀具路径规划参数，如切削步长和刀具倾斜角，对叶片电极微圆角的轮廓粗糙度有显著影响。本文提出了球头铣刀加工叶片电极微圆角的残留高度模型。利用所提出的残留高度模型预测了切削步长和刀具倾斜角对加工微圆角轮廓粗糙度的影响。然后对切削步长和刀具倾斜角进行优化，以确保微圆角形状要求的轮廓精度。最后生成刀具路径规划，并通过铣削实验验证加工策略。还发现当切削步长减小到一定值时，由于尺寸效应，轮廓粗糙度会变差。
