Virtual Minimization of Residual Stress and Deflection Error in Five-Axis Milling of Turbine Blades

To simulate and analyze the real machined parts in virtual environments, virtual machining systems are applied to the production processes. Due to friction, chip forming and the heat produced in the cutting zone, produced parts using machining operation is with residual stress. The machining force and machining temperature can cause the deflection error in the machined turbine blades which should be minimized to increase accuracy of machined blades. To minimize the residual stress and deflection error of machined parts, optimized machining parameters can be obtained. In the present research work, application of a virtual machining system is presented to predict and minimize the residual stress and deflection error in 5-axis milling operations of turbine blades. In order to predict the residual stress and deflection error in machined turbine blades, finite element analysis is implemented. Moreover, to minimize the residual stress and deflection error in machined turbine blades, optimized parameters of machining operations are obtained by using the Genetic algorithm. To validate the research work, experimentally determined residual stress by using the X-ray diffraction method from the machined turbine blades are compared with the finite element results obtained from the virtual machining system. Also, in order to obtain the deflection error, the machined blades are measured by using the CMM machines. So, accuracy and reliability of machined turbine blades can be increased by analyzing and minimizing the residual stress and deflection error in virtual environments