To read the full version of this content please select one of the options below:

Modeling and performance analysis of machining fixture for near-net-shaped jet engine blade

Hui Wang (Department of Mechanical Engineering, State Key Laboratory of Tribology, Beijing Key Lab of Precision/Ultra-Precision Manufacturing Equipment and Control, Tsinghua University, Beijing, China)
Jingsong Peng (Department of Mechanical Engineering, State Key Laboratory of Tribology, Beijing Key Lab of Precision/Ultra-Precision Manufacturing Equipment and Control, Tsinghua University, Beijing, China)
Bing Zhao (Department of Mechanical Engineering, State Key Laboratory of Tribology, Beijing Key Lab of Precision/Ultra-Precision Manufacturing Equipment and Control, Tsinghua University, Beijing, China)
Xin-Dong Zhang (Xi’an Aero-Engine (Group) Ltd., Xi’an, China)
Jie Yu (Xi’an Aero-Engine (Group) Ltd., Xi’an, China)
Yuan Li (Xi’an Aero-Engine (Group) Ltd., Xi’an, China)
Mao-Min Wang (Xi’an Aero-Engine (Group) Ltd., Xi’an, China)

Assembly Automation

ISSN: 0144-5154

Article publication date: 26 June 2019

Issue publication date: 3 October 2019

Abstract

Purpose

Near-net-shaped processes of jet engine blade have better performance in both reducing the material waste during production and improving work reliability in service, while the geometric features of blade, both sculptured surface and thin-walled shape, make the precise machining of blade challenging and difficult owing to its dynamics behaviors under complex clamping and machining loads. This paper aims to present a fundamental approach on modeling and performance analysis of the blade–fixture system.

Design/methodology/approach

A computerized framework on the complex blade–fixture dynamic behavior has been developed. Theoretical mechanic analysis on blade fixturing and machining is proposed with an especial emphasis on the boundary conditions of the blade–fixture system. Then the finite element analysis (FEA) method is used to simulate the variation trend of preloads, stiffness and blade distortion. The strong influence of parameters of workpiece–fixture configuration on blade distortion and machining error is investigated.

Findings

With a case of real jet engine blade machining, the experimental results and theoretical predictions suggest good agreement on their variation tendency. The loaded pressure of clamps has a critical influence on the total stiff performance of the blade–fixture system, and the profile error of the blade contributes much to the inconsistency in geometric dimension and surface integrity of blades’ machining. In the end, the results also validate the effectiveness of this methodology to predict and improve the performance of the blade–fixture configuration design.

Originality/value

The adaptive machining of near-net-shaped jet engine blade is a new high-performance manufacturing technology in aerospace production. This study provides a fundamental methodology for the performance analysis of blade-fixture system, to clear the variation law of blade distortion during preloading and machining, which will contribute to minimize the machining error and improve productivity.

Keywords

Acknowledgements

The authors would like to acknowledge the support and contributions of colleagues in Xi’an Aero-Engine (Group) Ltd. This research is supported partially by Xi’an Aero-Engine (Group) Ltd. and National Natural Science Foundation of China (Grant 51575310).

Citation

Wang, H., Peng, J., Zhao, B., Zhang, X.-D., Yu, J., Li, Y. and Wang, M.-M. (2019), "Modeling and performance analysis of machining fixture for near-net-shaped jet engine blade", Assembly Automation, Vol. 39 No. 4, pp. 624-635. https://doi.org/10.1108/AA-08-2018-113

Publisher

:

Emerald Publishing Limited

Copyright © 2019, Emerald Publishing Limited