Point grinding and electrolytic point grinding of Udimet 720

Curtis, David Thomas (2011). Point grinding and electrolytic point grinding of Udimet 720. University of Birmingham. Ph.D.

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Abstract

The work within this Thesis is concerned with the manufacturing processes associated with the production of blade root mounting slots in aeroengine compressor and turbine discs. Typically slots are of dovetail or fir-tree geometry dependent on specific design requirements. The state of the art process across the industry is broaching however, despite achieving required geometrical tolerances and surface integrity for decades the process is not without its disadvantages. Primarily these include the inflexibility of the process, machine tool cost; size and cutting forces, complexity of tooling and set up and further the limited level of control of the process beyond tooling design.

This has led to research into alternative processes across a range of conventional and non-conventional manufacturing techniques. Work presented here focuses on two key technology areas, namely point grinding and electrolytic point grinding. The former applies small diameter single layer grinding wheels on a high speed machining centre with spindle capability in the region of 60,000rpm. Target geometry was a complex fir-tree root form requiring dimensional control to within +/- 5um and a surface integrity in line with critical aerospace components. The later process investigated the unification of point grinding and electrochemical machining on a vertical machining centre to assess process performance across a range of variables.

Type of Work:

Thesis (Doctorates > Ph.D.)

Award Type:

Doctorates > Ph.D.

Supervisor(s):