Distortion during the forging or machining processes of a blade causes problems in subsequent manufacturing. This paper proposes an alternative multipoint correction method integrated with blade measurement, determination of correcting parameters, and adjustment of the correcting die. An iterative algorithm for determining the correcting parameters is proposed. Measuring equipment combining a laser displacement sensor with multipoint flexible support is manufactured to measure the blade shape. Multipoint correcting equipment with an adaptive lower die and rapid adjustment is manufactured, and software is developed for data analysis and equipment control. The correction experiment for a rough-machined steam-turbine blade indicates that the correcting parameters can be determined after one modification based on numerical simulation, and that a rough blade that meets the allowance for finish machining can be obtained using the determined correction parameters.
The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00440-6
Da-Wei Zhang
,
Wen-Long Gao-Zhang
,
Qi Zhang
. Alternative flexible correction forming of a blade: multipoint correction with surface measurement and deformation simulation[J]. Advances in Manufacturing, 2023
, 11(4)
: 587
-600
.
DOI: 10.1007/s40436-023-00440-6
1 Lin JG (2019) Fundamentals of materials modelling for metals processing technologies: theories and applications. In: Zhou KC, Lin YC, Song M et al (eds), translated. Central South University Press, Changsha
2 Chen F, Zhu H, Chen W et al (2021) Multiscale modeling of discontinuous dynamic recrystallization during hot working by coupling multilevel cellular automaton and finite element method. Int J Plast 145:103064. https://doi.org/10.1016/j.ijplas.2021.103064
3 Fang X, Zhang L, Chen G et al (2021) Microstructure evolution of wire-arc additively manufactured 2319 aluminum alloy with interlayer hammering. Mater Sci Eng A 800:140168. https://doi.org/10.1016/j.msea.2020.140168
4 Fang X, Yang J, Wang S et al (2022) Additive manufacturing of high performance AZ31 magnesium alloy with full equiaxed grains: microstructure, mechanical property, and electromechanical corrosion performance. J Mater Process Technol 300:117430. https://doi.org/10.1016/j.jmatprotec.2021.117430
5 Hu ZM, Dean TA (2011) Aspects of forging of titanium alloy and the production of blade forms. J Mater Process Technol 111:10-19
6 Yang H, Zhan M, Liu YL (2002) A 3D rigid-viscoplatic FEM simulation of the isothermal precision forging of a blade with a damper platform. J Mater Process Technol 122:45-50
7 Ou H, Lan J, Armstrong CG et al (2006) Reduction in post forging errors for aerofoil forging using finite element simulation and optimization. Model Simul Mater Sci Eng 14:179-193
8 Bruschi S, Ghiotti A (2008) Distortions induced in turbine blades by hot forging and cooling. Int J Mach Tool Manuf 48:761-767
9 Wan N, Shi S, Zhao H et al (2019) Localization method for precision forged blade edge considering multiple constraints. Int J Adv Manuf Technol 104:4641-4653
10 Huang T, Zhang XM, Ding H (2017) Tool orientation optimization for reduction of vibration and deformation in ball-end milling of thin-walled impeller blades. Procedia CIRP 58:210-215
11 Yang J, Zhang D, Wu B et al (2015) A path planning method for error region grinding of aero-engine blades with free-form surface. Int J Adv Manuf Technol 81:717-728
12 Mansour G (2014) A developed algorithm for simulation of blade to reduce the measurement points and time on coordinate measuring machine (CMM). Measurement 54:51-57
13 He W, Zhong K, Li Z et al (2018) Accurate calibration method for blade 3D shape metrology system integrated by fringe projection profilometry and conoscopic holography. Opt Laser Eng 110:253-261
14 Sun B, Li B (2015) A rapid method to achieve aero-engine blade form detection. Sensors 15:12782-12801
15 Guo CS, Zhang H, Yao ZK et al (2007) Study of influence of different isothermal adjustment process routes on titanium alloy blade profile. Forg Stamp Technol 32(4):105-108
16 Liu P, Zong YY, Shan DB et al (2013) Study on load relaxation based on hot bending and sizing of Ti6Al4V alloy sheet. AIP Conf Proc 1532:317-323
17 Lu L, Guo K, Sun J et al (2019) Investigation on hot sizing process based on creep mechanism for laser cladded thin-walled titanium alloy components. J Laser Appl 31:042002. https://doi.org/10.2351/1.5079879
18 Iriondo E, Alcaraz JL, Daehn GS et al (2013) Shape calibration of high strength metal sheets by electromagnetic forming. J Manuf Process 15:183-193
19 Ueda T, Wakimura Y, Furumoto T et al (2011) Experimental investigation on laser flattening of sheet metal. Opt Laser Eng 49:137-144
20 Zhang DW, Fan XG (2018) Review on intermittent local loading forming of large-size complicated component: deformation characteristics. Int J Adv Manuf Technol 99:1427-1448
21 Li M, Liu Y, Su S et al (1999) Multi-point forming: a flexible manufacturing method for a 3-d surface sheet. J Mater Process Technol 87:277-280
22 He T (2006) CAD/CAM for die. Peking University Press, Beijing
23 Zhang DW, Yang GC, Zhao SD (2021) Frictional behavior during cold ring compression process of aluminum alloy 5052. Chin J Aeronaut 34(5):47-64
24 Zhang DW, Liu BK, Li JX et al (2020) Variation of friction conditions in cold ring compression tests of medium carbon steel. Friction 8(2):311-322
25 Wu SD, He SJ (1987) Stamping Technology. Northwestern Polytechnical University Press, Xi’an
