Modeling the Process of Blades Shaping with Intraoperative Correction of Cutting Parameters

Abstract

The blades of gas turbine engines have a complex shape of the profiled part and low rigidity. In blade manufacture, there occur feather geometry errors, exceeding the tolerances of feather’s shape and dimensions. To minimize these errors, we propose a technological chain of mechanical processing of a blade on adaptively controlled machine tools, in which various cutting parameters and the trajectory of the cutting tool are adjusted to obtain the required geometry of the part. The use of intraoperative control allows calculating the correction value depending on the deviations of the actual parameters from the nominal ones. We built an ideal mathematical model, which will serve as the basis for the nominal shape of the blade, as well as a corrected geometric model of the blade for the subsequent operation. To calculate the correcting values ??of the parameters, we propose to use the mirror and secant methods. The mirror method consists in adding the error caused by the previous machining process to the current nominal depth of cut. The secant method is to express the nominal depth of cut of the next process as the sum of the nominal depth of cut of the previous process and the correction value. These methods make it possible to take into account the errors arising from previous operations.