MODELING OF SHARP EDGE SMOOTHING OF TURBINE BLADES ANGULAR FANS BY THE METHOD OF ED MILLING OPERATION ON MULTI-AXIS CNC MACHINES

The article views efficiency improving issues, quality and accuracy of sharp edge smoothing for numerous angular fans in the turbine blades of gas turbine engines made of heat-resistant nickel alloys and used in modern growing passenger aviation transport based on the development of ED milling new technology for modern multi-axis CNC machines with a rotating hollow electrode and a high-pressure fluidsupply of a special flush through the electrode body. An automated process for sharp edge machining has been developed for the production of more than 200 differently placed angular fans with a diameter of 0,45…0,6 mm in one blade instead of labor-intensive manual benchwork, where various needles, abrasive and metal rotary files are used. It is found that modeling and the development of special software resulted in a uniform radius of smoothing with high accuracy due to automatic ED milling operation along the entire trailing edge of each angular hole in the turbine blades at a multi-axis machining electro discharge center. The use of a rounded edge of the outlet ports provides more efficient cooling of the turbine blades and higher performance of gas turbine engines. At the same time, it is found that with a significant efficiency improving in blade sharp edge machining, a higher quality of the rounded edge surfaces in the holes is ensured. The results of the conducted research are recommended for the adoption of technologies in the aircraft engine industry.

turbine blades, sharp edges, rounded radius, ED milling operation, surface quality, programming, electrode trajectory