Development Of Cutting-Database For Aero Engine Components With Process Features Analysis

Aero engines are composed by casing, blade, shaft and disc-type parts which have complex structure and difficult-to-machine materials. The cutting parameters are traditionally selected based on personal programming experience, which will lead to low machining quality and low machining efficiency. In order to obtain optimized cutting parameters for aircraft engine’various kinds of technological features, cutting-database for aero engine components based on process features analysis is developed on the basis of finite element simulation of machining process, process features pedigree and the underlying data structure.Firstly, the business requirements and technical requirements analysis about cutting-database for aero engine components is performed. The solution strategy was put forward with finite element simulation model as a means of cutting data acquisition, the cutting database system, and integrate with UG CAM based on process features.Then, the process features are classified according to the machining methods, tool type and tool path of aero engine. Process features pedigree is developed. In addition, an accurate and practical prediction model for simulation of cutting temperature is proposed based on the Johnson-Cook constitutive equation, UG modeling and Deform 3D simulation. The effects of the material properties and fracture criterion on cutting temperature are simulated. The mathematical relationship between cutting temperature and the inclucing factors such as process parameters, cutting parameters and tool geometry parameters is established with multiple regressions. The cutting data are determined according to Makarov cutting temperature conversation law, which is stored using.dat format. Data structure of cutting-database for aero engine components based on process features analysis is established.Finally, on the basis of process features pedigree and the cutting data structure, considering the constraints from machined surface roughness, maximum machine tool spindle rotation speed and cutting force, cutting parameters software of the process feature are developed. The developed software adopts the MFC module of Microsoft Visual Studio 2010. It is integrated with UG CAM module, the seamless link between selection of cutting parameters for aero engine and UG CAM module is realized. Automatic reading and modifying of cutting data are then implemented. As a case study, selection of cutting parameters and cutting process are analyzed by using the developed cutting-database for aero engine components.Cutting-database for aero engine components based on process features analysis has solved the problem effectively, in which programmers define the cutting parameters of CNC machining by their experiences, leading to the rationality of cutting parameters varies from person to person and low processing efficiency.