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《中国航空学报(英文版)》 2018-01
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An investigation on adaptively machining the leading and tailing edges of an SPF/DB titanium hollow blade using free-form deformation

Zhengcai ZHAO;Jiuhua XU;Yucan FU;Zhiqiang LI;College of Mechanical and Electrical Engineering,Nanjing University of Aeronautics and Astronautics;Beijing Aeronautics Manufacturing Technology Research Institute;  
Titanium hollow blades are characterized with lightweight and high structural strength,which are widely used in advanced aircraft engines nowadays.Superplastic forming/diffusion bonding(SPF/DB) combined with numerical control(NC) milling is a major solution for manufacturing titanium hollow blades.Due to the shape deviation caused by multiple heat and pressure cycles in the SPF/DB process, it is hard to manufacture the leading and tailing edges by the milling process.This paper presents a new adaptive machining approach using free-form deformation to solve this problem.The actual SPF/DB shape of a hollow blade was firstly inspected by an on-machine measurement method.The measured point data were matched to the nominal SPF/DB shape with an improved ICP algorithm afterwards, by which the point-pairs between the measurement points and their corresponding points on the nominal SPF/DB shape were established, and the maximum modification amount of the final nominal shape was constrained.Based on the displacements between the point-pairs, an accurate FFD volume was iteratively calculated.By embedding the final nominal shape in the deformation space, a new final shape of the hollow blade was built.Finally, a series of measurement and machining tests was performed, the results of which validated the feasibility of the proposed adaptive machining approach.
【Fund】: the financial supports of the National Natural Science Foundation of China(No.51475233);; the Fundamental Research Funds for Central Universities(No.NZ2016107);; the Jiangsu Innovation Program for Graduate Education(No.CXLX13_139)
【CateGory Index】: V263
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