Virtual minimization of residual stress and deflection error in the five-axis milling of turbine blades

Soori, Mohsen (author), Asmael, Mohammed (author)

To simulate and analyse the real machined parts in virtual environments, virtual machining systems are applied to the production processes. Due to friction, chip forming, and the heat produced in the cutting zone, parts produced using machining operation have residual stress effects. The machining force and machining temperature can cause the deflection error in the machined turbine blades, which should be minimized to increase the accuracy of machined blades. To minimize the residual stress and deflection error of machined parts, optimized machining parameters can be obtained. In the present research work, the application of a virtual machining system is presented to predict and minimize the residual stress and deflection error in a five-axis milling operations of turbine blades. In order to predict the residual stress and deflection error in machined turbine blades, finite element analysis is implemented. Moreover, to minimize the residual stress and deflection error in machined turbine blades, optimized parameters of machining operations are obtained by using a genetic algorithm. To validate the research work, experimentally determining residual stress by using a X-ray diffraction method from the machined turbine blades is compared with the finite element results obtained from the virtual machining system. Also, in order to obtain the deflection error, the machined blades are measured by using the CMM machines. Thus, the accuracy and reliability of machined turbine blades can be increased by analysing and minimizing the residual stress and deflection error in virtual environments.

• Language: English
• Keywords: virtual machining, residual stress, deflection error, parameter optimization, turbine blades
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2021
• Number of pages: Str. 235-244
• Numbering: Vol. 67, no. 5
• PID: 20.500.12556/RUL-128415
• UDC: 621.22-253
• ISSN on article: 0039-2480
• DOI: 10.5545/sv-jme.2021.7113
• COBISS.SI-ID: 69920515
• Publication date in RUL: 12.07.2021

Record is a part of a journal

• Title: Strojniški vestnik
• Shortened title: Stroj. vestn.
• Publisher: Zveza strojnih inženirjev in tehnikov Slovenije [etc.], = Association of Mechanical Engineers and Technicians of Slovenia [etc.
• ISSN: 0039-2480
• COBISS.SI-ID: 762116

Secondary language

• Language: Slovenian
• Title: Zmanjšanje preostalih napetosti in napak odklona z virtualnim petosnim rezkanjem turbinskih lopatic
• Keywords: virtualna obdelava, preostale napetosti, napaka odklona, optimizacija parametrov, turbinske lopatice, petosni CNC-obdelovalni stroji