A review of 5-axis milling techniques for centrifugal impellers: Tool-path generation and deformation control

Centrifugal impellers (CIs) boast advantages such as compact structure, lightweight characteristics, and high single-stage pressure ratio. These benefits make them essential across sectors such as aerospace, energy and power, and automotive. The manufacturing process of impellers plays a crucial rol...

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Published inJournal of manufacturing processes Vol. 131; pp. 160 - 186
Main Authors Zhou, Yu, Jiang, Yiming, Lu, Chen, Huang, Jiamin, Pei, Jinze, Xing, Tong, Zhao, Shuai, Zhu, Kun, Yan, Huansong, Xu, Zheng, Ding, Shuiting
Format Journal Article
LanguageEnglish
Published Elsevier Ltd 12.12.2024
Subjects
5-Axis milling
Centrifugal impellers
Error control
Machining deformation
Tool-path planning
5-Axis milling
Machining deformation
Tool-path planning
Centrifugal impellers
Error control
Online AccessGet full text
ISSN1526-6125
DOI10.1016/j.jmapro.2024.08.049

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Abstract Centrifugal impellers (CIs) boast advantages such as compact structure, lightweight characteristics, and high single-stage pressure ratio. These benefits make them essential across sectors such as aerospace, energy and power, and automotive. The manufacturing process of impellers plays a crucial role in determining their aerodynamic performance and production costs. It demands attention to diverse processing methods, the distinctive features of free-form surface and thin-walled blades, and factors affecting manufacturing accuracy and efficiency. Consequently, the manufacturing technologies for impeller machining have become the focal point of current research. The 5-axis milling manufacturing process for CIs has been extensively analyzed and reviewed. This thorough review scrutinizes and contrasts the attributes of 5-axis end milling and flank milling methods, covering processing principles, unique characteristics, and the implications of tool geometry. Regarding these two milling methods, the paper summarizes the current research findings on milling strategies for free-form surface blade fabrication and the evaluation and management of errors and deformations in the machining of thin-walled blades. Moreover, it delves into the challenges and innovative technological solutions in tool-path planning and deformation control within 5-axis milling. This paper aims to furnish technical guidance for the manufacture of CIs, thereby charting a path towards the realization of high-performance and cost-efficient CIs.
AbstractList Centrifugal impellers (CIs) boast advantages such as compact structure, lightweight characteristics, and high single-stage pressure ratio. These benefits make them essential across sectors such as aerospace, energy and power, and automotive. The manufacturing process of impellers plays a crucial role in determining their aerodynamic performance and production costs. It demands attention to diverse processing methods, the distinctive features of free-form surface and thin-walled blades, and factors affecting manufacturing accuracy and efficiency. Consequently, the manufacturing technologies for impeller machining have become the focal point of current research. The 5-axis milling manufacturing process for CIs has been extensively analyzed and reviewed. This thorough review scrutinizes and contrasts the attributes of 5-axis end milling and flank milling methods, covering processing principles, unique characteristics, and the implications of tool geometry. Regarding these two milling methods, the paper summarizes the current research findings on milling strategies for free-form surface blade fabrication and the evaluation and management of errors and deformations in the machining of thin-walled blades. Moreover, it delves into the challenges and innovative technological solutions in tool-path planning and deformation control within 5-axis milling. This paper aims to furnish technical guidance for the manufacture of CIs, thereby charting a path towards the realization of high-performance and cost-efficient CIs.
Author Lu, Chen
Huang, Jiamin
Xing, Tong
Pei, Jinze
Jiang, Yiming
Zhou, Yu
Zhao, Shuai
Ding, Shuiting
Zhu, Kun
Xu, Zheng
Yan, Huansong
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  fullname: Xing, Tong
  organization: Research Institute of China Telecom Co., Ltd., Beijing, China
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  surname: Zhao
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  organization: Research Institute of Aero-Engine, Beihang University, Beijing, China
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  fullname: Zhu, Kun
  organization: Aero Engine Academy of China, China
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  organization: AVIC Nanjing Engineering Institute of Aircraft Systems, Nanjing, China
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  givenname: Zheng
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  fullname: Xu, Zheng
  email: zheng.xu@buaa.edu.cn
  organization: Hangzhou International Innovation Institute, Beihang University, Hangzhou, China
– sequence: 11
  givenname: Shuiting
  surname: Ding
  fullname: Ding, Shuiting
  organization: Research Institute of Aero-Engine, Beihang University, Beijing, China
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crossref_primary_10_3390_met15010071
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Keywords 5-Axis milling
Machining deformation
Tool-path planning
Centrifugal impellers
Error control
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Snippet Centrifugal impellers (CIs) boast advantages such as compact structure, lightweight characteristics, and high single-stage pressure ratio. These benefits make...
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StartPage 160
SubjectTerms 5-Axis milling
Centrifugal impellers
Error control
Machining deformation
Tool-path planning
Title A review of 5-axis milling techniques for centrifugal impellers: Tool-path generation and deformation control
URI https://dx.doi.org/10.1016/j.jmapro.2024.08.049
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