Skip to main content
Springer Nature Link
Log in

Alternative flexible correction forming of a blade: multipoint correction with surface measurement and deformation simulation

  • Published:
Advances in Manufacturing Aims and scope Submit manuscript

Abstract

Distortion during the forging or machining processes of a blade causes problems in subsequent manufacturing. This paper proposes an alternative multipoint correction method integrated with blade measurement, determination of correcting parameters, and adjustment of the correcting die. An iterative algorithm for determining the correcting parameters is proposed. Measuring equipment combining a laser displacement sensor with multipoint flexible support is manufactured to measure the blade shape. Multipoint correcting equipment with an adaptive lower die and rapid adjustment is manufactured, and software is developed for data analysis and equipment control. The correction experiment for a rough-machined steam-turbine blade indicates that the correcting parameters can be determined after one modification based on numerical simulation, and that a rough blade that meets the allowance for finish machining can be obtained using the determined correction parameters.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
$34.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or eBook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19

Similar content being viewed by others

Explore related subjects

Discover the latest articles and news from researchers in related subjects, suggested using machine learning.

References

  1. Lin JG  (2019) Fundamentals of materials modelling for metals processing technologies: theories and applications. In: Zhou KC, Lin YC, Song M et al (eds), translated. Central South University Press, Changsha

  2. Chen F, Zhu H, Chen W et al (2021) Multiscale modeling of discontinuous dynamic recrystallization during hot working by coupling multilevel cellular automaton and finite element method. Int J Plast 145:103064. https://doi.org/10.1016/j.ijplas.2021.103064

    Article  Google Scholar 

  3. Fang X, Zhang L, Chen G et al (2021) Microstructure evolution of wire-arc additively manufactured 2319 aluminum alloy with interlayer hammering. Mater Sci Eng A 800:140168. https://doi.org/10.1016/j.msea.2020.140168

    Article  Google Scholar 

  4. Fang X, Yang J, Wang S et al (2022) Additive manufacturing of high performance AZ31 magnesium alloy with full equiaxed grains: microstructure, mechanical property, and electromechanical corrosion performance. J Mater Process Technol 300:117430. https://doi.org/10.1016/j.jmatprotec.2021.117430

    Article  Google Scholar 

  5. Hu ZM, Dean TA (2011) Aspects of forging of titanium alloy and the production of blade forms. J Mater Process Technol 111:10–19

    Article  Google Scholar 

  6. Yang H, Zhan M, Liu YL (2002) A 3D rigid-viscoplatic FEM simulation of the isothermal precision forging of a blade with a damper platform. J Mater Process Technol 122:45–50

    Article  Google Scholar 

  7. Ou H, Lan J, Armstrong CG et al (2006) Reduction in post forging errors for aerofoil forging using finite element simulation and optimization. Model Simul Mater Sci Eng 14:179–193

    Article  Google Scholar 

  8. Bruschi S, Ghiotti A (2008) Distortions induced in turbine blades by hot forging and cooling. Int J Mach Tool Manuf 48:761–767

    Article  Google Scholar 

  9. Wan N, Shi S, Zhao H et al (2019) Localization method for precision forged blade edge considering multiple constraints. Int J Adv Manuf Technol 104:4641–4653

    Article  Google Scholar 

  10. Huang T, Zhang XM, Ding H (2017) Tool orientation optimization for reduction of vibration and deformation in ball-end milling of thin-walled impeller blades. Procedia CIRP 58:210–215

    Article  Google Scholar 

  11. Yang J, Zhang D, Wu B et al (2015) A path planning method for error region grinding of aero-engine blades with free-form surface. Int J Adv Manuf Technol 81:717–728

    Article  Google Scholar 

  12. Mansour G (2014) A developed algorithm for simulation of blade to reduce the measurement points and time on coordinate measuring machine (CMM). Measurement 54:51–57

    Article  Google Scholar 

  13. He W, Zhong K, Li Z et al (2018) Accurate calibration method for blade 3D shape metrology system integrated by fringe projection profilometry and conoscopic holography. Opt Laser Eng 110:253–261

    Article  Google Scholar 

  14. Sun B, Li B (2015) A rapid method to achieve aero-engine blade form detection. Sensors 15:12782–12801

    Article  Google Scholar 

  15. Guo CS, Zhang H, Yao ZK et al (2007) Study of influence of different isothermal adjustment process routes on titanium alloy blade profile. Forg Stamp Technol 32(4):105–108

    Google Scholar 

  16. Liu P, Zong YY, Shan DB et al (2013) Study on load relaxation based on hot bending and sizing of Ti6Al4V alloy sheet. AIP Conf Proc 1532:317–323

    Google Scholar 

  17. Lu L, Guo K, Sun J et al (2019) Investigation on hot sizing process based on creep mechanism for laser cladded thin-walled titanium alloy components. J Laser Appl 31:042002. https://doi.org/10.2351/1.5079879

    Article  Google Scholar 

  18. Iriondo E, Alcaraz JL, Daehn GS et al (2013) Shape calibration of high strength metal sheets by electromagnetic forming. J Manuf Process 15:183–193

    Article  Google Scholar 

  19. Ueda T, Wakimura Y, Furumoto T et al (2011) Experimental investigation on laser flattening of sheet metal. Opt Laser Eng 49:137–144

    Article  Google Scholar 

  20. Zhang DW, Fan XG (2018) Review on intermittent local loading forming of large-size complicated component: deformation characteristics. Int J Adv Manuf Technol 99:1427–1448

    Article  Google Scholar 

  21. Li M, Liu Y, Su S et al (1999) Multi-point forming: a flexible manufacturing method for a 3-d surface sheet. J Mater Process Technol 87:277–280

    Article  Google Scholar 

  22. He T (2006) CAD/CAM for die. Peking University Press, Beijing

    Google Scholar 

  23. Zhang DW, Yang GC, Zhao SD (2021) Frictional behavior during cold ring compression process of aluminum alloy 5052. Chin J Aeronaut 34(5):47–64

  24. Zhang DW, Liu BK, Li JX et al (2020) Variation of friction conditions in cold ring compression tests of medium carbon steel. Friction 8(2):311–322

    Article  Google Scholar 

  25. Wu SD, He SJ (1987) Stamping Technology. Northwestern Polytechnical University Press, Xi’an

    Google Scholar 

Download references

Acknowledgements

This work was supported in part by the Fundamental Research Funds for the Central Universities (Grant Nos. xtr012019004 and zrzd2017027) and the Shaanxi Province Key Research and Development Projects (Grant No. 2021GXLH-Z-049).

Author information

Authors and Affiliations

  1. Xi’an Key Laboratory of Intelligent Equipment and Control, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, 710049, People’s Republic of China

    Da-Wei Zhang, Wen-Long Gao-Zhang & Qi Zhang

Authors
  1. Da-Wei Zhang
    View author publications

    You can also search for this author inPubMed Google Scholar

  2. Wen-Long Gao-Zhang
    View author publications

    You can also search for this author inPubMed Google Scholar

  3. Qi Zhang
    View author publications

    You can also search for this author inPubMed Google Scholar

Corresponding author

Correspondence to Da-Wei Zhang.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhang, DW., Gao-Zhang, WL. & Zhang, Q. Alternative flexible correction forming of a blade: multipoint correction with surface measurement and deformation simulation. Adv. Manuf. 11, 587–600 (2023). https://doi.org/10.1007/s40436-023-00440-6

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40436-023-00440-6

Keywords