Simulation And Verification Of Five-axis NC EDM Of Integral Turbine Blisk Based On Compressed Voxel Model

The integral turbine blisk is a new type structural part of aero-engine, which is the critical component of the aero-engine. It has complicated shape and precise profile requirement. Its blade is a free form surface and the space between each others is narrow even distorted. The integral turbine blisk is usually made of high-performance metallic and composite materials with poor workability. Its manufacture is the key in the processing of aero-engine. At present, the multi-axis NC electrical discharge machining (EDM) is the most effective way to machine the integral turbine.This thesis studies several three-dimensional geometric modeling methods commonly used in the simulation of NC machining based on the presentation of geometric modeling, and summarizes their advantages and disadvantages. The voxel model is the main emphasis of research, and the modeling principle and method of compressed voxel model is studied.The modeling algorithm and Boolean algorithm is accomplished. Presenting the display of voxel, the disadvanges of classic Marching Cubes algorithm is analysised and an optimized Marching Cubes algorithm for compressed voxel model is accomplished which improves the efficiency of extraction of surface. On the base of above work, this thesis adopts compressed voxel model of workpiece and the swept volume of shaped electrode to do Boolean operation to simulate the maching process after workpiece and shaped electrode is modeled. Optimized Marching Cubes algorithm is applied to build the triangle mesh model of machined workpiece which can be observed in real time from any direction. After the simulation is finished, the machined workpiece is verified through comparing data extracted from the with the CAD model of integral turbine blisk.The method has been successfully applied to five-axis NC machining of the integral turbine blisk, which achieved excellent effect.