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.
Simplification of a G-Code Feeding Path in Roughing Multi-Axis Electrical Discharging Machining for Shrouded Blisks With a Contour Error Constraint
Manuscript received September 24, 2016; final manuscript received July 28, 2017; published online September 13, 2017. Assoc. Editor: Y. B. Guo.
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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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