Optimised methodology for aircraft engine IBRs five-axis machining process

Abstract

Integral bladed rotors (IBRs), such as impeller and blisk, have become five-axis machining reference components. Due to its functional and technical requirements, these parts consist of complex geometry and are manufactured in difficult to cut materials. Despite the recent advances in five-axis machining, these components manufacturing is still a challenge. In the present work a methodology for a reliable machining process of IBRs is proposed. Geometric and process simulations were added to the initial toolpath design process in order to improve obtained part quality. A machine kinematics simulation allowed optimising machining set up. In addition, a mechanical analysis was developed to simulate the cutting forces. Several impeller and blisk geometries were milled to validate and optimise the process.