Verification of blade NC machining program
The blade is one of the most critical components in a steam turbine, with its steam passage section playing a key role in determining the turbine’s power output and directly impacting the quality of the final product. As China's steam turbine industry continues to grow, blade design has also evolved, particularly in the development of variable-section twisted blades. These blades feature complex spatial geometry, requiring high-precision machining that is difficult to achieve. To improve efficiency and reduce heat consumption, Harbin Turbine Co., Ltd. has collaborated with 3D companies to develop advanced manufacturing techniques. The blade’s steam inlet and outlet fins are thin, and the tip and root have small radii, making the entire machining and inspection process highly demanding. A multi-axis CNC machine tool is essential for processing such intricate parts, and ensuring the accuracy of the NC machining program before actual production is crucial.
Blade NC machining involves complex 3D surface modeling. B-Spline surfaces are used to fit the blade’s shape data points, and factors like tool width, step size, and tool radius are considered during interpolation. This process generates detailed coordinates for the NC program, which must be carefully prepared. For medium-length blades, there can be tens of thousands of operations, leading to long program segments, large coordinate spans, and potential errors in four- or five-axis programs. These challenges make manual verification impractical and error-prone.
Common mistakes in NC machining programs include tool collisions, incorrect tool radius selection, improper feed rates, and invalid program formats. Such issues can lead to rework, repair, or even scrapping of parts, delaying production and reducing the reliability of CNC technology. Therefore, verifying NC programs is not only important theoretically but also practically.
Manual inspection is time-consuming and inefficient for complex blade geometries. Test processing using non-metallic materials provides a visual check of the machining process, but it is slow and resource-intensive. Computer simulation offers a more efficient solution by displaying tool paths, models, and tool positions on a screen. This allows engineers to detect overcutting, tool interference, and pathåˆç†æ€§ before actual machining begins.
Display verification is a widely used method, especially for blade tips and roots. It involves showing the tool path alongside the machined surface, allowing real-time observation of tool movement. By reversing post-processing calculations, the tool’s position and orientation can be accurately displayed. This method ensures smooth tool path connections, avoids sudden changes in the tool axis, and confirms that the cutting direction aligns with the surface model. Visual checks from different angles help ensure precision and prevent errors. Overall, display verification is an intuitive and effective way to validate NC programs, especially for complex blade structures.
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