Simulation And Experiment For The Twisted Thin-Walled Part Of Blades Of Machining Deformation

Aero-engine is the heart of a plane, the safety and reliability in the working process ofthe engine are the important premises for modern aircrafts to improve the tactical performanceand prolong the service life. With generations of the new type high-performance aero-engineappearing continuously, the manufacturing technology of aero-engine is developing rapidly,and the technical improvement of blades is one of the most significant embodiments.The paper aims at the deformation problem of aero-engine blades in the working process,a dynamic simulation method for blades is proposed, based on the interference-free tool pathgenerated by NC program. The geometric accuracy and the surface quality of the blades arepredicted, and the error compensation is conducted to decrease deformation error and improvethe machining quality.Firstly, in order to apply the load exactly in the simulation of milling processing, theGauss curvature of the blade surface is analyzed, interference-free tool path is generated byNC simulation modules of UG software. The milling force is calculated based on the Oxleytheory, which laid a theoretical foundation for the simulation analysis.Secondly, make a dynamic finite element simulation for the milling process of a blade.Johnson-Cook material model and the shear model are built; three different schemes, flankmilling, turnover milling and spiral milling are studied for the simulation of milling process.Research on the surface residual stress and the deformation of the blade, a better millingscheme is selected.Thirdly, make a milling simulation for the blisk blade by using the optimized millingscheme. By single factor milling simulation of milling parameter, study is carried out on theinfluence rule of milling deformation and surface quality by milling parameters selected.Finally, based on the deformation result of simulation analysis, the multiple cycle reversedeformation error compensation method is taken for the blisk blade. The error compensationof the blisk blade is ensured in the designing tolerance. The correctness and effectiveness of the finite element simulation method is verified based on the machining experiment.