Deformation Error Compensation in 5-Axis Milling Operations of Turbine Blades

The precision and performance of machined parts can be affected by deformation errors in flexible part end milling. So, deformation errors prediction and compensation during milling operations of flexible parts can provide a key tool in accuracy enhancement of part production. In this study, an improved virtual machining system is used to assess and correct deformation errors caused by cutting temperature and forces in flexible part 5-axis milling operations. The improved Johnson-Cook model is utilized to investigate the cumulative impact of strain rate and deformation temperatures on flow stress during turbine blade machining process. To estimate deformation errors caused by cutting forces and temperature on the workpiece and cutting tool, the finite element analysis is applied. Then, volumetric vectors of deformation error at each cutting location along the machining pathways are generated in order to be compensated within new machining tool paths. As a result, the deformation error created by cutting forces and temperature on the workpiece and cutting tool are compensated in order to enhance accuracy during 5-axis milling operation of flexible turbine blades. Experiments are carried out using a 5-axis CNC machine tool and errors are quantified using a CMM to verify the study's developed strategy. As a consequence, precision of machining operations on flexible turbine blades can be enhanced by employing the methods presented in the study.