Transcript Correction of toolpaths

Finish Milling of Impeller Blade
Peter Klein
Concepts NREC
Step Manufacturing Demonstration
1.Oct.2008
Closed Loop Machining
Who is Concepts NREC?
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Independent company specializing in
turbomachinery technology.
Involved in all technical disciplines related to
turbomachinery.
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cycle analysis; fluid / aerodynamic; stress / vibration;
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thermal / mechanical; rotordynamics, bearings, seals;
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manufacturing; life prediction; troubleshooting; and
combustion.
Headquarters in Wilder, VT
Business Units
Engineering and Testing Services
Products (Equipment /
Manufacturing Services)
CAE/CAM Software:
The Agile Engineering System
Product Center in Woburn, MA
• CAM Software Development
• In-house machine shop
– Contract machining
– Product development
• 5-axis Machines
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Hermle C40U
Mikron HSM-600U
Mitsui Seiki HS5A-80
BostoMatic 1000
• Support and test equipment
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2 lathes
Spin pits
Balancing
Zeiss CMM
MAX-PAC™ CAM Software
• Commercial product
developed by
Concepts NREC
since 1985
• Specialized for 5axis milling of
impellers and blisks
MAX-PAC CAM Suite
MAX-5
Flank-milling of ruled-surface blades
MAX-AB
Point-milling of free-form blades
MAX-SI
Integrally shrouded
Example Geometry Data
• Ruled-surface
impeller blade
• 99x2 grid of XYZ
points
Model Construction
• MAX-5 reads data
grid and constructs
surface model
• Automatic
constructions:
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Round lead edge
Blunt trail edge
Tip/Hub trim
Fillet
Toolpaths
Roughing
Hub Finish
Blade Finish
Lead Edge
Fillet Finish
Finish Toolpath
• Flank milling toolpath
generated by MAX-5
• Forms blade in one pass
using side of cutter
• Patented algorithm
minimizes geometric
deviation
• Toolpath file formats
– APT(XYZIJK)
– Postprocessed
Inspection Path
• 5-axis inspection
• Inspect at each input grid
point along tip (inset 1
mm to ensure contact)
• Skip off-part points at
lead and trail
• 97 points per side
• Measures deflection at
blade tip
• Ignore tool deflection at
blade root for this demo
• Modified Siemens format
CMM Feedback
• Text file contains
inspection results
• Specifies deviation at
each blade grid point
• Missing values
smoothly interpolated
• Used as MAX-5
feedback input to
adjust blade
Adjusted Geometry
• Blade has been
adjusted in highdeflection lead edge
area at tip
• Blade can be
thickened (shown
here) or thinned
Adjusted Toolpath
• New toolpath
automatically
generated by MAX-5
using deviation data
• Batch-mode possible
with no user
interaction