The Five-Axis NC Milling Process Of Physical Simulation Analysis Of Centrifugal Impeller Blades

As the heart of airplane, Aero-engine is the strategic industry of a country. The centrifugal impeller blades as the key parts of aero-engine, its machining accuracy and surface quality affect the property of aero-engine directly. At present, the turbofan has been produced in our country, like as'Tai Hang', but the property of domestic engine is worse than that in US, Russia, UK and France. Except for the reason of insufficient funds, the main reason is that the level of manufacturing process is rather backward, and what leads to the poor level are as follows: lacking of dates and experience accumulating, no fully considering of the integration influence of cutting deformation and cutting parameters on machining accuracy and surface quality. And how to optimize the NC machining process and achieve the high-efficiency and high quality processing of centrifugal impeller blades is an important project in the aero-engine research. Therefore, it is urgent to conduct the researches on processing physical simulation and experiment for five-axis CNC milling centrifugal impeller blades in order to advance the NC machining process optimum proposal. Thus, the means of cutting basic theory, finite element numerical simulation, five-axis NC machining and the software UG and developer kits are adopted to explore the technologies of machining physical simulation of five-axis CNC milling centrifugal impeller blades, and the relations between machining deformation and cutting parameters are revealed, and the strategies of the process optimum are established in this paper. Specific studies are as follows:1) In this paper, the research status of machining process physical simulation, milling force modeling, and the technic planning and optimization of centrifugal impeller blades are reviewed. And then the trend of the development of machining physical simulation and machining quality control of complex thin-walled surface are analyzed.2) The flank milling force model of tapered helical ball end mill is established. Based on the geometric structure characteristics of tapered helical ball end mill and the processing mechanism of flank milling, the flank milling force model is established by using cutting theory, cutting mechanics theory. And the flank milling force model is perfected by the orthogonal machining experiment. The experimental results indicate that the flank milling force model of tapered helical ball end mill is reliable by comparing the predicted milling force value with the actual measured milling force value. This works laid the foundation of subsequent researches.3) Five-axis NC milling physical simulation and cutting deformation simulation of centrifugal impeller blades is carried out based on the dedicated FEA machining physical simulation software AdvantEdge and general FEM software ANSYS.4) Based on the above analysis, the machining technic optimize strategies are presented. On one hand, the tool axis is modified to compensate the deflection errors, and on the other hand, the spindle speeds are adjusted with changing of different cutting zone to ameliorate the surface quality. Finally, the results of FE physical simulation show that the proposed optimize strategies are reliable and efficient.In summary, the effective solution is provided to advance the high efficiency and high quality of five-axis NC milling centrifugal impeller blades. And the theory foundation is established to expand the technology of machining physical simulation to complex curved surfaces machining.