Multi-axis electrical discharging machining (EDM) is the main manufacture method for shrouded blisks, which are key components of aero and rocket engines. Involving both linear and rotational axes, a feeding path for machining a narrow and twisted channel consists of a large number of G-code lines. Accelerations and decelerations at junctions, which connect two neighboring G-code lines, can significantly reduce the machining efficiency. In this paper, a new simplification of feeding paths in roughing EDM for shrouded blisks is proposed in order to reduce the number of junctions on a feeding path. However, deviating from the original feeding path, a simplified feeding path can bring over contour errors which can cause geometrical errors of workpieces. Contour error can thus serve as a criterion for simplifying the original path. Eight vertices of a hexahedron, which contains the electrode, are used to represent all points inside and on an electrode. Forward kinematics of a six-axis EDM machine is used to calculate the contour errors of the eight vertices when the electrode feeds along a simplified path. A simplified feeding path can be found provided that the contour error constraint is respected. Machining tests show that the use of a simplified feeding path in roughing EDM machining can reduce the average total machining time by 26.5% without significant impact on surface roughness and white layer thickness.
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November 2017
Research-Article
Simplification of a G-Code Feeding Path in Roughing Multi-Axis Electrical Discharging Machining for Shrouded Blisks With a Contour Error Constraint
Xue-Cheng Xi,
Xue-Cheng Xi
State Key Laboratory of Mechanical
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: xixuecheng@gmail.com
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: xixuecheng@gmail.com
Search for other works by this author on:
Hao Chen,
Hao Chen
State Key Laboratory of Mechanical
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: billychen8948@hotmail.com
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: billychen8948@hotmail.com
Search for other works by this author on:
Wan-Sheng Zhao
Wan-Sheng Zhao
State Key Laboratory of Mechanical
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: zws@sjtu.edu.cn
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: zws@sjtu.edu.cn
Search for other works by this author on:
Xue-Cheng Xi
State Key Laboratory of Mechanical
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: xixuecheng@gmail.com
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: xixuecheng@gmail.com
Hao Chen
State Key Laboratory of Mechanical
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: billychen8948@hotmail.com
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: billychen8948@hotmail.com
Wan-Sheng Zhao
State Key Laboratory of Mechanical
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: zws@sjtu.edu.cn
System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: zws@sjtu.edu.cn
1Corresponding author.
Manuscript received September 24, 2016; final manuscript received July 28, 2017; published online September 13, 2017. Assoc. Editor: Y. B. Guo.
J. Manuf. Sci. Eng. Nov 2017, 139(11): 111013 (9 pages)
Published Online: September 13, 2017
Article history
Received:
September 24, 2016
Revised:
July 28, 2017
Citation
Xi, X., Chen, H., and Zhao, W. (September 13, 2017). "Simplification of a G-Code Feeding Path in Roughing Multi-Axis Electrical Discharging Machining for Shrouded Blisks With a Contour Error Constraint." ASME. J. Manuf. Sci. Eng. November 2017; 139(11): 111013. https://doi.org/10.1115/1.4037569
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