AI Chat Paper
Discover the SciOpen Platform and Achieve Your Research Goals with Ease.
Search articles, authors, keywords, DOl and etc.
{{expandStatus?'Exit ':''}}Advanced Search
This article presents a comprehensive review on the machining technology of aero-engine casings. The material removal mechanism of mechanical machining and nontraditional machining is introduced in the first part. Then, several mechanical machining technologies of aero-engine casings (e.g. numerical control machining, turn-milling complex machining, machining vibration suppression) are summarized. Subsequently, the research progress and academic achievements are explored in detail in terms of the electrochemical machining, electric discharging machining and ultrasonic machining in the field of nontraditional machining technology of aero-engine casings. Finally, the existing challenges in mechanical machining technology and nontraditional machining technology of aero-engine casings are analyzed, and the developing tendencies to aero-engine casings machining is proposed.
Kang HH, Li ZM. Assembly research of aero-engine casing involving bolted connection based on rigid-compliant coupling assembly deviation modeling. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 2020; 234(14): 2803-2820.
Kang HH, Li ZM, Liu T, et al. Tolerance design of multistage aero-engine casing assembly by vibration characteristicevaluation. Journal of Aerospace Engineering 2021; 34(5): 04021064.
Hou LL, Cao SQ. Evaluation method for vibration measurement on casing in aeroengine: Theoretical analysis and experimental study. Shock and Vibration 2019; (9); 1-15.
Bi C, Zhang LP, Dong P, et al. Study on measuring method of radial geometrical deformation of the fixture fringe of casing. Applied Optics and Photonics China 2019; 11338: 1-8.
Guo L, Yang F, Li T, et al. Vibration suppression of aeroengine casing during milling. International Journal of Advanced Manufacturing Technology 2021; 113(1-2): 295-307.
Li D, Hu CH, Tan BN, et al. An aeroengine measurement system based on high-precision turntable. Applied Optics and Photonics China 2019; 11336: 1-8.
Yang SY, Chen C, Liu GW. An experimental and simulation study of impact resistance in sandwich structures casing. Proceedings of the Institution of Mechanical Engineers, Part G: Journal of Aerospace Engineering 2019; 233(10): 3635-3648.
Zhou N, Liu X. Feature-based automatic NC programming for aero-engine casings. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 2019; 233(4): 1289-1301.
Ren JX, Tian WJ, Yao CF, et al. Research on key technology of aeroengine casing CNC machining. Aeronautical Manufacturing Technology 2016; 5: 73-77[Chinese].
Rajaratnam S, Hyde TH, Leen SB. Characterisation of a simplified aeroengine casing subjected to a radial loading condition using FE and approximate methods. Proceedings of ESDA, 2006.p.1-9.
Huang DW, Liu CF, Zhang XY, et al. Fatigue test method on full-scale aeroengine turbine casing. AIAA/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference, 2018.
Gonzalo O, Seara JM, Guruceta E, et al. A method to minimize the workpiece deformation using a concept of intelligent fixture. Robotics and Computer-Integrated Manufacturing 2017; 48: 209-218.
Turner R, Huang JL, Ward M, et al. On the modelling of a pulsed TIG weld process in a nickel superalloy. Materials Science Forum 2013; 762:531-537.
Ezugwu EO, Bonney J, Yamane Y. An overview of the machinability of aeroengine alloys. Journal of Materials Processing Technology 2003; 134(2): 233-253.
Xi XX, Ding WF, Fu YC, et al. Grindability evaluation and tool wear during grinding of Ti2AlNb intermetallics. International Journal of Advanced Manufacturing Technology 2018; 94(1-4): 1441-1450.
Wang ZB, Sun JF, Chen WY, et al. Machining distortion of titanium alloys aero engine case based on the energy principles. Metals 2018; 8:1-18.
Liu ZW, Liu XM, Huang Y, et al. CNC abrasive belt grinding technology and equipment for aeroengine casing welding. Aeronautical Manufacturing Technology 2014; 73-77[Chinese].
Chai SL, Ouyang LH, Bi QZ, et al. An adaptive fixture for suppress vibrations and measuring workpiece deformation of thin-walled casings. Procedia CIRP 2021; 101: 322-325.
Möhring HC, Wiederkehr P. Intelligent fixtures for high performance machining. Procedia CIRP 2016; 46: 383-390.
Zhou X, Zhang DH, Luo M, et al. Chatter stability prediction in four-axis milling of aero-engine casings with bull-nose end mill. Chinese Journal of Aeronautics 2015; 28(6): 1766-1773.
Wang DY, Zhu ZW, Wang HR, et al. Convex shaping process simulation during counter-rotating electrochemical machining by using the finite element method. Chinese Journal of Aeronautics 2016; 29(2): 534-541.
Li HN, Li SQ. The mathematic model for EDM removal mechanism and the discussion for the EDM efficiency enhancement method of case profile. China Measurment&Test 2018; 44: 191-195. (In Chinese)
Dong TJ, Chen J, Ding HP. High-speed cutting machining simulation of aero engine casing hole. Advanced Materials Research 2014; 915-916:1014-1017.
Yu B. Application of electromachining technology in aeroengine. Metal Working 2013; 22[Chinese].
Kolluru K, Axinte D. Coupled interaction of dynamic responses of tool and workpiece in thin wall milling. Journal of Materials Processing Technology 2013; 213(9): 1565-1574.
Ge YC. Basic research on electrochemical machining for superalloy casing. Nanjing University of Aeronautics and Astronautics 2018. (In Chinese)
Peng ZL, Zhang DY, Zhang XY. Chatter stability and precision during high-speed ultrasonic vibration cutting of a thin-walled titanium cylinder. Chinese Journal of Aeronautics 2020; 33(12): 3535-3549.
Pawade RS, Joshi SS. Mechanism of chip formation in high-speed turning of inconel 718. Machining Science and Technology 2011; 15(1): 132-152.
Thakur A, Gangopadhyay S. Evaluation of micro-features of chips of Inconel 825 during dry turning with uncoated and chemical vapour deposition multilayer coated tools. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 2018; 232(6): 979-994.
Korlos A, Friderikos O, Sagris D, et al. Experimental analysis of Ti6Al4V orthogonal cutting. Key Engineering Materials 2016; 665: 17-20.
Prakash M, Kanthababu M, Rajurkar KP. Investigations on the effects of tool wear on chip formation mechanism and chip morphology using acoustic emission signal in the microendmilling of aluminum alloy. International Journal of Advanced Manufacturing Technology 2015; 77 (5-8): 1499-1511.
Álvarez R, Domingo R, Sebastián MÁ. Investigation of Ti6Al4V orthogonal cutting numerical simulations using different material models. AIP Conference Proceedings 2010; 1252: 787-794.
He LJ, Su HH, Xu JH, et al. Study on dynamic chip formation mechanisms of Ti2AlNb intermetallic alloy. International Journal of Advanced Manufacturing Technology 2017; 92(9-12): 4415-4428.
Dai CW, Yu TY, Ding WF, et al. Single diamond grain cutting-edges morphology effect on grinding mechanism of Inconel 718. Precision Engineering 2019; 55: 119-126.
Behera BC, Chetan SG, Paruchuri VR, et al. Study of saw-tooth chip in machining of Inconel 718 by metallographic technique. Machining Science and Technology 2019; 23(3): 431-454.
Pramanik A, Islam MN, Basak A, et al. Machining and tool wear mechanisms during machining titanium alloys. Advanced Materials Research 2013; 651: 338-343.
Pramanik A, Basak AK, Littlefair G, et al. Methods and variables in electrical discharge machining of titanium alloy–A review. Heliyon 2020; 6(12): 05554.
Ruszaj A, Cygnar M, Grabowski M. The state of the art in electrochemical machining process modeling and applications. AIP Conference Proceedings, 2018.
Ali MN, Doloi B, Sarkar BR. Electrochemical discharge machining technology applied for turning operation. IOP Conference Series: Materials Science and Engineering 2019; 653: 012029.
Hourmand M, Sarhan AAD, Sayuti M, et al. A comprehensive review on machining of titanium alloys. Arabian Journal for Science and Engineering 2021; 46(8): 7087-7123.
Camp DV, Qian J, Vleugels J, et al. Experimental investigation of the process behaviour in mechano-electrochemical milling. CIRP Annals-Manufacturing Technology 2018; 67(1): 217-220.
Camp DV, Bouquet J, Qian J, et al. Investigation on hybrid mechano-electrochemical milling of Ti6Al4V. Procedia CIRP 2018; 68: 156-161.
Wang ML, Qu NS. Investigation on material removal mechanism in mechano-electrochemical milling of TC4 titanium alloy. Journal of Materials Processing Technology 2021; 295: 117206.
Kaushal SB, Narayan A. Experimental setup development and parametric study of electrochemical face grinding process using Ni-based superalloy. International Journal of Abrasive Technology 2020; 10(1): 1-15.
Yu TB, Yang XZ, An JH, et al. Material removal mechanism of two-dimensional ultrasonic vibration assisted polishing Inconel718 nickel-based alloy. International Journal of Advanced Manufacturing Technology 2018, 96(1-4): 657–667.
Chen G, Ren CZ, Zou YH, et al. Mechanism for material removal in ultrasonic vibration helical milling of Ti–6Al–4V alloy. International Journal of Machine Tools and Manufacture 2019; 138: 1-40.
Luo HP, Wang B, Ji J. Research on NC machining technology of typical aero engine parts. Machinery 2017; 55: 46-49[Chinese].
Wang ZH, Yin HF. Numerical Control Machining and manufacturing technology analysis of mechanical die based on computer data control system. International Conference on Computer Applied Science and Information Technology 2020; 213(9): 1565-1574.
Zhou X, Luo M, Zhang DH, et al. Cutting force prediction in four-axis milling of curved surfaces with bull-nose end mill. Procedia CIRP 2016; 56: 100-104.
Wang YT, Wang D, Zhang SZ, et al. Design and development of a five-axis machine tool with high accuracy, stiffness and efficiency for aero-engine casing manufacturing. Chinese Journal of Aeronautics 2022;35(4):485-496.
Li ZR, Zou L, Yin JC, et al. Investigation of parametric control method and model in abrasive belt grinding of nickel-based superalloy blade. International Journal of Advanced Manufacturing Technology 2020; 108(9-10):3301–3311.
Zhang MD, Chen TN, Tan YN, et al. An adaptive grinding method for precision-cast blades with geometric deviation. International Journal of Advanced Manufacturing Technology 2020; 108(7-8):2349-2365.
Zeng QS, Guo HB, Li DW. Robotic grinding of casing air passage and support plate surface. Diamond&Abrasives Engineering 2021; 6(41): 7-11[Chinese].
Chen F, Zhao H, Li DW, et al. Robotic grinding of a blisk with two degrees of freedom contact force control. International Journal of Advanced Manufacturing Technology 2019; 101(1-4): 461-474.
Xu XH, Chen W, Zhu DH, et al. Hybrid active/passive force control strategy for grinding marks suppression and profile accuracy enhancement in robotic belt grinding of turbine blade. Robotics and Computer-Integrated Manufacturing 2021; 67: 102047.
Xiao GJ, Huang Y. Adaptive belt precision grinding for the weak rigidity deformation of blisk leading and trailing edge. Advances in Mechanical Engineering 2017; 9(10): 1-12.
Jin X, Liu B, Zhang ZJ, et al. Research on automatic processing code generation system technology of micro-turning and milling combined machine. International Conference on Advanced Electronic Materials, Computers and Materials Engineering, 2019: 032026.
Berenji KR, Kara ME, Budak. investigating high productivity conditions for turn-milling in comparison to conventional turning. 8th CIRP Conference on High Performance Cutting, 2018, 77: 259-262.
Kolluru KV, Axinte DA, Raffles MH, et al. Vibration suppression and coupled interaction study in milling of thin wall casings in the presence of tuned mass dampers. Journal of Engineering Manufacture 2014; 228(6): 826-836.
Nakano Y, Kishi T, Takahara H. Experimental study on application of tuned mass dampers for chatter in turning of a thin ‐ walled cylinder. Applied Sciences 2021; 11(12070): 1-23.
Falta J, Janota M, Sulitka M. Chatter suppression in finish turning of thin-walled cylinder: Model of tool workpiece interaction and effect of spindle speed variation. Procedia CIRP 2018; 77: 175-178.
Quintana G, Ciurana J. Chatter in machining processes: A review. International Journal of Machine Tools & Manufacture 2011; 51: 363-376.
Kolluru K, Axinte D, Becker A. A solution for minimising vibrations in milling of thin walled casings by applying dampers to workpiece surface. CIRP Annals - Manufacturing Technology 2013; 62(1): 415-418.
Kolloru K, Axinte D. Novel ancillary device for minimising machining vibrations in thin wall assemblies. International Journal of Machine Tools and Manufacture 2014; 85: 79-86.
Xiang HY, Xiao Y. Research on anti-flutter processing of aeroengine casing. Electronics Science Technology and Application 2021; 8(1): 1-6.
Wang H, Zhu D, Liu J. Improving the accuracy of the blade leading/trailing edges by electrochemical machining with tangential feeding. CIRP Annals - Manufacturing Technology 2019; 68: 165-168.
Skoczypiec S, Lipiec P, Bizon W, et al. Selected aspects of electrochemical micromachining technology development. Materials 2021; 14(9): 1-24.
Ge YC, Zhu ZW, Zhu M, et al. Tool design and experimental study on electrochemical turning of nickel-based cast superalloy. Journal of the Electrochemical Society 2018; 165(5): 162-167.
Leese R, Ivanov A. Electrochemical micromachining: Review of factors affecting the process applicability in micro-manufacturing. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 2018; 232(2): 195-207.
Wang DY, Zhu ZW, He B, et al. Counter-rotating electrochemical machining of a combustor casing part using a frustum cone-like cathode tool. Journal of Manufacturing Processes 2018; 35: 614-623.
Demirtas H, Yilmaz O, Kanber B. A simplified mathematical model development for the design of free-form cathode surface in electrochemical machining. Machining Science and Technology 2017; 21(1): 157-173.
Ge YC, Zhu ZW, Zhu YW. Electrochemical machining of nickel-based cast casing using a cylindrical rotating electrode. International Journal of Electrochemical Science 2019; 14(9): 8439-8449.
He B, Wang DY, Zhu ZW, et al. Research on counter-rotating electrochemical machining of convex structures with different heights. International Journal of Advanced Manufacturing Technology 2019; 104(5-8): 3119-3127.
Li HY, Zhag MQ, Feng J, et al. Development and application of mask electrochemical machining technology. Aeronautical Manufacturing Technology 2015; 23/24: 57-60[Chinese].
Lin GM, Peng LX. Electrical discharge machining technology and its latest application. Advanced Materials Research 2012; 487: 515-519.
Maity KP, Choubey M. A review on vibration-assisted EDM, micro-EDM and WEDM. Surface Review and Letters 2019; 26:1-29.
Baroi BK, Jagadish, Patowari PK. A review on sustainability, health, and safety issues of electricaldischarge machining. Journal of the Brazilian Society of Mechanical Sciences and Engineering 2022; 44-59.
Zhao WS, Kang XM, Gu L. Application of electrical discharge machining technology in aerospacemanufacturing. Acta Aeronautica et Astronautica Sinica 2022[Chinese].
Antar M, Chantzis D, Marimuthu S, et al. High speed EDM and laser drilling of aerospace alloys. Procedia CIRP 2016; 42: 526-531.
Holmberg J, Berglund J, Wretland A, et al. Evaluation of surface integrity after high energy machining with EDM, laser beam machining and abrasive water jet machining of alloy 718. International Journal of Advanced Manufacturing Technology 2019; 100(5-8): 1575-1591.
Khajehzadeh M, Ahmadpoor SS, Raftar OR, et al. Process parameters infuence on cutting force and surface roughness during hybrid laser and ultrasonic elliptical vibration‑assisted machining. Journal of the Brazilian Society of Mechanical Sciences and Engineering 2021; 43(1): 1-17.
Sharma A, Kalsia M, Uppal AS, et al. Machining of hard and brittle materials: A comprehensive review. Materials Today: Proceedings 2022; 50: 1048-1052.
Dixit US, Pandey PM, Verma GC. Ultrasonic-assisted machining processes: a review. International Journal Mechatronics and Manufacturing Systems 2019; 12:227-254.
Singh KJ, Ahuja IS; Kapoor J. Ultrasonic, chemical-assisted ultrasonic and rotary ultrasonic machining of glass: a review paper. World Journal of Engineering 2018; 15:1-39.
Sui H, Zhang XY, Zhang DY, et al. Feasibility study of high-speed ultrasonic vibration cutting titanium alloy. Journal of Materials Processing Technology 2017; 247: 111-120.
Peng ZL, Zhang XY, Zhang DY. Integration of finishing and surface treatment of Inconel 718 alloy using high-speed ultrasonic vibration cutting. Surface and Coatings Technology 2021; 413(37): 127088.
Guo H, Zhou CC, Wang KK, et al. Simulation of ultrasonic vibration cutting performance of GH2132 superalloy. Materials Science and Engineering 2019; 493: 012162.
He Y, Zhou ZM, Zou P, et al. Study of ultrasonic vibration–assisted thread turning of Inconel 718 superalloy. Advances in Mechanical Engineering 2019; 11(10): 1-12.
Tong JL, Zhao JS, Chen P, et al. Effect of ultrasonic elliptical vibration turning on the microscopic morphology of aluminum alloy surface. International Journal of Advanced Manufacturing Technology 2020; 106(3-4): 1397-1407.
Liu JJ, Jiang XG, Han X, et al. Influence of parameter matching on performance of high-speed rotary ultrasonic elliptical vibration-assisted machining for side milling of titanium alloys. International Journal of Advanced Manufacturing Technology 2019; 101(5-8): 1333-1348.
This is an Open Access article distributed under the terms of the Creative Commons Attribution License http://creativecommons.org/licenses/by/4.0)，which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
京公网安备11010802044758号