A PROJECT REPORT ON MANUFACTURING OF A GT COMPRESSOR BLADE USING 5-AXIS MILLING METHOD AND COMPARISION OF THE RESULTS WITH 3-AXIS MILLING METHOD A report submitted for partial fulfillment of the B.Tech Degree in Mechanical Engineering Submitted by G.Keerthana (10011P0305) M.Vivekanand (10011P0311) Rabbani Kausar (10011P0314) Azaldeen Eltaher Mohamed (10011P0319) Under the esteemed guidance of Dr. M. Sreenivasa Rao Professor DEPARTMENT OF MECHANICAL ENGINEERING JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY KUKATPALLY, HYDERABAD – 500 085 (A.P.) APRIL-2014 DEPARTMENT OF MECHANICAL ENGINEERING JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY COLLEGE OF ENGINEERING, HYDERABAD-500085
83
Embed
Manufacturing of a GT compressor blade on a 5-axis milling machine
This project report is very valuable in learning the manufacturing process of a GT compressor blade on a 5-axis milling machine.
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
A PROJECT REPORT ON
MANUFACTURING OF A GT COMPRESSOR BLADE USING
5-AXIS MILLING METHOD AND COMPARISION OF THE
RESULTS WITH 3-AXIS MILLING METHOD
A report submitted for partial fulfillment of the B.Tech Degree in
Mechanical Engineering
Submitted by
G.Keerthana (10011P0305)
M.Vivekanand (10011P0311)
Rabbani Kausar (10011P0314)
Azaldeen Eltaher Mohamed (10011P0319)
Under the esteemed guidance of
Dr. M. Sreenivasa Rao
Professor
DEPARTMENT OF MECHANICAL ENGINEERING
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY
KUKATPALLY, HYDERABAD – 500 085 (A.P.)
APRIL-2014
DEPARTMENT OF MECHANICAL ENGINEERING
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY
COLLEGE OF ENGINEERING, HYDERABAD-500085
DEPARTMENT OF MECHANICAL ENGINEERING
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY
COLLEGE OF ENGINEERING, HYDERABAD-500085
CERTIFICATE
This is to certify that the project report entitled “MANUFACTURING OF A GT
COMPRESSOR BLADE USING 5-AXIS MILLING METHOD AND
COMPARISION OF THE RESULTS WITH 3-AXIS MILLING METHOD”, has been
submitted by G.Keerthana (10011P0305), M.Vivekanand (10011P0311), Rabbani Kausar
(10011P0314), Azaldeen Eltaher Mohamed (10011P0319) in partial fulfillment of the
requirements for the award of degree of “BACHELOR OF TECHNOLOGY IN
MECHANICAL ENGINEERING” to the JNTUH COLLEGE OF ENGINEERING
HYDERABAD. This is a record of bonafide work carried out by them. The results of
investigations enclosed in this report have been verified and found to be satisfactory.
The results embodied in this report have not been submitted to any other university for
the award of any Degree or Diploma.
PROJECT GUIDE: HEAD OF THE DEPARTMENT:
Dr.M. Sreenivasa Rao Dr.B. Sudheer Prem Kumar
Professor (M.Tech., Ph.D. F.I.E (I))
Dept. of Mechanical Engineering Professor and Head
JNTUH College of Engineering Dept. of Mechanical Engineering
Hyderabad. JNTUH College of Engineering
Hyderabad.
i | P a g e
ACKNOWLEDGEMENT
This is an acknowledgement of the intensive drive and technical competence of many
individuals who have contributed to the success of our project.
I am immensely thankful to Mr. G. Madhavulu, Additional General Manager, TDL,
BHEL R&D, HYD for providing me the opportunity to carry out this project in such a reputed
organization.
I am very grateful to Mr. S. Srinu, Sr. Engineer, TDL, BHEL R&D, HYD for his
sagacious guidance and valuable suggestions during the course of our project.
My sincere thanks to Dr. B. Sudheer Prem Kumar, Head of Mechanical Engineering
Department, JNTUHCEH, Hyderabad, for granting us permission to carry out this project in
BHEL R&D, Hyderabad.
I would like to thank my internal guide Dr. M. Sreenivasa Rao, Professor, JNTUHCEH,
Hyderabad, for his encouragement and cooperation and all other staff members for the support
and motivation provided.
I like to extend my thanks to Mr. S. Biswas, General Manager, TDL, and members of
HRD for granting me permission for practical training through development of this project in
BHEL R&D, Hyderabad.
I like to express my gratitude to all members of TDL Dept. who were friendly and co-
operative
ii | P a g e
CONTENTS
CHAPTER 1 INTRODUCTION 1
1.1 Introduction 1
1.2 Scope of present work 2
CHAPTER 2 LITERATURE REVIEW 3
2.1 Turbine and Compressor Blades 3
2.2 Gas turbine blade design 3
2.2.1 Blade Design Process 4
2.2.2 Parametric Blade Design System 5
2.2.3 Parametric Blade Representation 5
CHAPTER 3 MODELLING AND 5-AXIS TOOL PATH 7
GENERATION OF GT COMPRESSOR BLADE
3.1 Introduction to NX 7.5 7
3.1.1 NX CAD 7
3.1.2 NX CAM 8
3.2 Modelling of GT Compressor Blade 8
3.3 Drawings of GT compressor Blade 11
3.4 Blade Modelling 12
3.4.1 Part Navigator 15
3.5 Generation of 5- Axis Tool Paths 16
3.5.1 Creation of Blank 16
3.5.2 Setting Manufacturing Environment 18
3.5.3 Creating a New Operation 19
3.5.3.1 Roughing 19
3.5.3.2 Semifinishing 24
3.5.3.3 Finishing 28
3.6 Operation Navigator 31
iii | P a g e
3.7 Simulation Compressor of Tool paths 31
3.7.1 Verify 31
CHAPTER 4 MANUFACTURING OF GT COMPRESSOR 34
BLADE
4.1 Blade Machining 34
4.2 Sturz milling method 34
4.2.1 Advantages of sturz milling 34
4.3 Machining the blade body 37
4.3.1 Roughing the Rombus 37
4.3.2 Semi finishing the blade 39
4.3.3 Finishing the blade 40
4.4 Post Processing 41
4.4.1 Post-processing sequence 42
4.4.1.1 NC Program 44
4.4.2 Post builder 46
4.5 Chiron 5-axis machine 47
4.5.1 Specifications 47
4.5.2 Components 48
4.5.3 Steps involved in machining the blade 49
CHAPTER 5 INSPECTION OF GT COMPRESSOR BLADE 53
USING 3D CMM
5.1 CMM Overview 53
5.1.1 Specifications 54
5.2 Camio V4.4 55
5.3 Inspection Procedure 56
5.3.1 Creating a Part Pragram 56
5.4 Inspection 57
5.5.1 Reporting 58
iv | P a g e
CHAPTER 6 RESULTS AND DISCUSSIONS 60
6.1 Roughed Part 60
6.2 Semi finished Part 61
6.3 Finished Part 62
6.4 GT Compressor Blade 63
6.5 Inspection Results 64
6.6 Comparison between CMM inspected GT blade profiles- 68
Machined with 3-axis and 5-axis methods
6.7 Conclusion 70
REFERENCES 71
REFERENCES 64
v | P a g e
LIST OF FIGURES
FIGURE 2.1 BLADE DESIGN PROCESS 4
FIGURE 2.2 PARAMETRIC BLADE REPRESENTATION 6
FIGURE 3.1 NX 7.5 9
FIGURE 3.2 NEW PART DIALOG 10
FIGURE 3.3 NX 7.5 USER INTERFACE 11
FIGURE 3.4 BLADE PROFILE 11
FIGURE 3.5 BLADE ROOT 12
FIGURE 3.6 BLADE COORDINATES 12
FIGURE 3.7 BLADE SECTIONS 13
FIGURE 3.8 ROOT MODEL IN NX 13
FIGURE 3.9 BLADE PROFILE GENERATION 14
FIGURE 3.10 BLADE MODEL 14
FIGURE 3.11 PART NAVIGATOR 15
FIGURE 3.12 CREATION OF BLANK 17
FIGURE 3.13 BLANK 17
FIGURE 3.14 STARTING MANUFACTURING 18
FIGURE 3.15 MANUFACTURING ENVIRONMENT 18
FIGURE 3.16 CREATE ROUGHING OPERATION 19
FIGURE 3.17 CAVITY MILLING 20
FIGURE 3.18 TOOL 20
FIGURE 3.19 NEW TOOL 21
vi | P a g e
FIGURE 3.20 MILLING TOOL 5-PARAMETERS 21
FIGURE 3.21 PATH SETTINGS 22
FIGURE 3.22 GENERATING PROGRAM 22
FIGURE 3.23 TOOL PATH ON PRESSURE SIDE 23
FIGURE 3.24 TOOL PATH ON SUCTION SIDE 23
FIGURE 3.25 CREATE SEMI FINISHING OPERATION 24
FIGURE 3.26 FIXED CONTOUR 24
FIGURE 3.27 FLAT END MILL 25
FIGURE 3.28 TOOL PATH GENERATION 25
FIGURE 3.29 SEMI FINISHING TOOL PATH WITH BLANK 26
FIGURE 3.30 SEMI FINISHING TOOL PATH WITHOUT BLANK 26
FIGURE 3.31 SEMI FINISHING TOOL PATH ON SUCTION SIDE 27
FIGURE 3.32 SEMI FINISHING TOOL PATH ON SUCTION SIDE 27
WITHOUT BLANK
FIGURE 3.33 CREATING FINISHING OPERATION 28
FIGURE 3.34 FIXED CONTOUR 28
FIGURE 3.35 SURFACE AREA DRIVE METHOD 29
FIGURE 3.36 GENERATE FINISHING TOOL PATH 29
FIGURE 3.37 FINISHING TOOL PATH ON PRESSURE SIDE 30
FIGURE 3.39 FINISHING TOOL PATH ON SUCTION SIDE 30
Type of machine controller and different parameters suited for machine are
specified in post builder
Figure 4.11 Post builder
47 | P a g e
4.5 CHIRON 5-AXIS MACHINE
Figure 4.12 chiron 5-axis machining centre
4.5.1 SPECIFICATIONS
MANUFACTURER: Chiron, Germany
Controller : Sinumeric 840D
Travel:
X-axis 800 mm
Y-axis 630 mm
Z-axis 550 mm
Spindle AC-motor17,0 kW at 100 % 47,2 kW at 5 % for mainspindle
Spindle speed range: 20 - 12.000 rpm - max.180 Nm
COLUMN MOVING MACHINING CENTRE with swing setup Linear-guide ways
with long-term grease lubrication
Digital direct drives AC-servo motors for x-, y- and z-axes with
direct absolute path Glass scales measuring system over pressured in all axes rapid
traverse in all axes 60 m/min. acceleration 0.5 m/s2
210 bar Hydraulic unit incl. valves for supply and clamping circuit for clamping of
faceplate and counter bearing complete with hydraulic connection
48 | P a g e
Scratch Band Chip conveyor and PF 50 / KFA 900 Coolant Equipment: tank
capacity 900 l, pump capacity from 100 l/min at 2,1 bar up to 250 l/min at 1,8 bar high
pressure pump capacity 20 l/min at 30 bar high pressure circuit with filtration via paper
bond filter, filtration
50 Rm nominal. Twin filter in the high pressure circuit for the protection of the machine.
No of tools : 24
No of axes: 5 axes continuous.
Max job weight: 300Kg.
4.5.2 COMPONENTS
NC swivel head
The NC swivel head with hydraulic clamping and water-cooled motor spindle has a
swivelling range of ± 110° and distinguishes itself by its exceptionally high rigidity,
overload capacity and speed.
CNC CONTROL
The MILL series can be delivered with a Siemens, Fanuc or Heidenhain CNC
control. A CNC machine controller runs G-code and M code programs and provides the
user interface between the machine and the operator. The controller is capable of full 5-
axes simultaneous motion.
AUTOMATIC TOOL CHANGE USING THE PICK-UP METHOD,
Starting from 1.5 s (24 / 40 / 60 tool places) The tool changing system is a quick,
failure-proof pick-up system. It takes only 1.5 s to change tools. The chain magazine with
24 (optionally 40) tool places is designed for tool holders with ISO 40 or HSK-A 63 and
separated from the working area. Tools with a diameter of up to 125 mm and length of up
to 280 mm can be used.
TOOL MAGAZINE
Tools are made available from the background magazine (92 or 165 ISO / CAT
40 or HSK-A 63 tool places) during machining. The intelligent tool management chain
serves as storage for frequently used tools. If more tools are required, a background
magazine can also be used during the machining operation. A total of 92 tools can be
used. These tools are assigned to specific magazine places with fixed codes and
are immediately brought back to their respective places after use.
49 | P a g e
4.5.3 STEPS INVOLVED IN MACHINING THE BLADE
Blank Selection and Measuring MCS by Optical Edge Finder
Figure 4.13 Measuring MCS by optical edge finder
Machining of Pressure Side using bull nose cutter of diameter 20mm and lower radius 6
mm
Figure 4.14 Machining pressure side
50 | P a g e
Machining of Suction Side using bull nose cutter of diameter 20mm and lower radius 6
mm
Figure 4.15 Machining suction side
Semi finishing operation done by flat end mill cutter of diameter 12mm on pressure side
51 | P a g e
Figure 4.16 Semi finishing on pressure side
Semi finish operation done by flat end mill cutter of diameter 12mm on suction side
Figure 4.17 Semi finish on suction side
The finishing of blade on pressure and also chamfer of the root is done by ball nose cutter
of 12mm dia.
52 | P a g e
Figure 4.18 Finishing on pressure side
Figure 4.19 Finishing on suction side
53 | P a g e
CHAPTER 5
INSPECTION OF GT COMPRESSOR BLADE USING
3D-CMM
5.1 CMM OVERVIEW
LK CMMs are available in various configurations based on overhead beam or
horizontal spindle designs. The CMM axes move on a cushion of air supplied by air
bearings and are assembled around a granite work surface. The granite work surface has a
number of drilled and tapped holes to allow for part location. The axes of the CMM allow
measurements to be made on a part or work piece in a Cartesian co-ordinate system.
Points are taken with a probe mounted on the Z axis spindle. The axes can be moved
manually with the joysticks on the hand box, or through CNC to facilitate probing and the
taking of points. Point data is supplied to a computer via the reading of digital encoders
on optical scales. There is one optical scale for each axis of the CMM. During correct
operation the CMM ‘knows’ the precise location of the probe as points are taken. The
axes are driven by motors acting either via belts or on drive bars. The CMM is connected
through an electronic control unit to a computer workstation. Output devices for the
computer comprise a VDU and printer and provision is also made for connection to a
network.
54 | P a g e
Figure 5.1 LK Ascent – 3D Coordinate Measuring Machine
5.1.1 Specifications
Name: 3D CNC CMM
Manufacturer: LK (Metris), UK
Model: Ascent
Type: Bridge
Range: 8.7.6
Controller: ACT
Application Software: Camio 4.4
55 | P a g e
5.2 Camio v 4.4
Metris Camio is the combined inspection and programming environment for CMMs. It is
available as a suite of metrology software solutions. Camio can allow you to create
inspection programs off-line from the 3D CAD model design, or by manually
programming on-line, or by a combination of these methods. It can provide full 3D
geometric modeling capabilities, and supports SAT®, IGES, VDA, CATIA® and other
file formats. Programs can be executed in manual or CNC (program or automatic) mode,
and the results reported in text or graphical format against the 3D CAD model.
Camio conforms to the specifications of the Dimensional Measuring Interface
Specification (DMIS). It is assumed that users are familiar with this specification and
with the basics of inspection using CMMs.
Figure 5.2 Camio Studio
56 | P a g e
5.3 INSPECTION PROCEDURE
The manufactured test blade and the heat treated test blades are inspected for
deviations using the 3D Coordinate Measuring Machine.
5.3.1 Creating a Part Program
When you create a new program, a template of DMIS commands is inserted in
your program. If Camio cannot find the DMIS template file that contains these
commands, it will create one for you.
To create a new part program, select New Program from the File menu. If you
wish to use any default tolerances you have previously defined using the Tolerance
dialog box, check the Use default tolerances box in the New Inspection dialog box (click
the Advanced button). Otherwise, any required tolerances must be defined in the part
program.
Check input, output, DTA, XML files in Output options.
Open the iges model file in Model options.
Check the CSV option in Reporting option.
Figure 5.3 Open Inspection Box
57 | P a g e
5.4 INSPECTION
The inspection is done by selecting a slice 100mm distance from bottom of the
blade.
The slice is made into number of divisions or spacing can also be given and values
are noted at these points are then read into the computer.
The Inspect measure icons allow the user to measure features.
The tolerance values are given in the tolerance command.
Then inspect curve option is selected to measure to measure the profile of blade.
Nominal values of the blade are also given as per the drawing.
Figure 5.4 Inspection using 3DCMM
58 | P a g e
Figure 5.5 Slice selection on profile
5.4.1 Reporting
LK Studio Reporting allows to output text and graphics reports from inspection
data. A report will be created by selecting LK Studio Reporting option.
The report can be obtained either in notepad or in excel sheets. Graphical reporting
can be obtained using digigraph.
The results give the deviations in blade by considering the actual, nominal and
tolerance values.
59 | P a g e
Figure 5.6 Tolerance specified
Figure 5.7 Digigraph values at 100mm distance from of plane bottom
60 | P a g e
CHAPTER 6
RESULTS AND DISCUSSIONS
The results of machining at different stages, like Roughing, semi finishing, and
finishing are discussed below. Also discussed are the results of inspection of specimen
blade.
6.1 Roughed part
This process begins with raw stock, known as billet, and cuts it very roughly to
shape of the final model. In milling, the result often gives the appearance of terraces,
because the strategy has taken advantage of the ability to cut the model horizontally.
Common strategies are zig-zag cleaning, offset cleaning, plunge roughing, rest roughing.
Figure 6.1 Rough Machined on Pressure side
61 | P a g e
Figure 6.2 Rough Machined on suction side
6.2 Semi-finished part
This process begins with a roughed part that unevenly approximates the model
and cuts to within a fixed offset distance from the model. The semi-finishing pass must
leave a small amount of material so the tool can cut accurately while finishing, but not so
little that the tool and material deflect instead of shearing.
Figure 6.3 Semi finished on pressure side
62 | P a g e
Figure 6.4 Semi finished on suction side
6.3 Finished part
Finishing involves a slow pass across the material in very fine steps to produce the finished part. In finishing, the step between one pass and another is minimal. Feed rates are low and spindle speeds are raised to produce an accurate surface.