Project Title: Surface Integrity Oriented Development of Machining Technologies
Academic Supervisor: Dr Adrian Sharman
AMRC Supervisor: Prof. Sam Turner
Sponsor: ITP Engines UK
Aerospace critical components need to be machined to a high standard in order to meet all the quality requirements. There are some complex machining (milling) operations which are performed with a very low productivity to meet the material’s surface and near-surface requirements. Through the EngD study, we are evaluating how improved machining techniques affect the final surface and near-surface of the machined component with the target of improving current milling processes.
Aerospace titanium blisk components are becoming increasingly popular in the new aircraft engines. They provide big benefits compared to traditional disc and blade assemblies, such as weight reduction and other benefits associated to being a single component. However, manufacturing of blisk components is more complex, especially the finish milling process of the blades. In some cases, 5 axis milling approach is required, and the flexible nature of the blades and the tool creates vibration (chatter) problems that affect the surface integrity of the final component. In order to overcome this issue, a very conservative finish milling approach is followed. Process damping is an interesting effect that appears in certain conditions when machining and solves chatter vibration issues. However, very little is known about how process damping affects to the surface integrity, being a roughing/ploughing effect. The objective of this study is to evaluate how process damping affects the surface integrity of the final component and therefore, propose an improved blade finish milling process.