Bell-Type Countersink Machining for Faster Blisk Channel Roughing
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Solution Overview
Problem
The production of blisks is time-consuming due to the complex geometry of blade profiles, which requires rough machining with side or end milling cutters, and often necessitates additional finishing with form milling cutters.
Innovation Solution
A method using a bell-type countersink with a conical lateral surface for 3-axial or 5-axial movement along a linear or curved path to reflect the blade profile geometry, reducing the need for form milling and simplifying programming, while minimizing tool stress and material fatigue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If side milling cutters or end milling cutters are used for rough machining, then the machining process can be performed with standard tools, but the time required for rough-machining is excessive and additional form milling cutters are needed
Solution Approach 1:
The bell-type countersink is designed to perform multiple functions: it serves as both a countersinking tool and a roughing tool capable of machining complex blade profile geometries. The tool combines the functionality of what would traditionally require separate side milling cutters, end milling cutters, and form milling cutters into a single multi-functional tool, thereby reducing the number of tool changes and setup operations while significantly reducing total machining time
2Productivity
If a bell-type countersink is used to better reflect blade profile geometry, then rough-machining time is reduced, but the tool may experience lateral pressure and stress
Solution Approach 1:
The bell-type countersink is designed with a specific conical geometry and structural characteristics that enable it to dynamically withstand the lateral pressures and stresses encountered during rough-machining operations. The tool's design allows it to flex and absorb forces while maintaining dimensional accuracy, preventing premature failure despite the demanding machining conditions
Solution Approach 2:
The method involves preliminary positioning and alignment of the bell-type countersink before machining begins. By pre-establishing the correct tool orientation and path, the design ensures that lateral forces are applied in controlled directions that the tool geometry is optimized to handle, preventing excessive stress concentrations that would lead to fatigue failure
3Manufacturing precision
If 5-axial movement is used for better alignment of bell-type countersink, then alignment precision is improved, but programming complexity increases
Solution Approach 1:
The complex 5-axial movement is segmented into simpler sequential operations. The machining process is divided into distinct phases: initial positioning, rough-machining passes, and finishing passes. Each phase uses a simplified toolpath that requires less complex programming, while the cumulative effect achieves the desired high-precision alignment through multiple controlled steps rather than a single complex motion
Data Source
AI summary
The invention relates to a method for producing a blisk comprising a plurality of blade profiles and channels extending between the blade profiles using a bell-type countersink having a conical lateral surface, wherein the method comprises the steps providing a disk-shaped blank, and, to form the channels in the blank, plunging the bell-type countersink into the blank on a lateral surface of the blank and thereby moving it in a direction along a generating line of the bell-type countersink, wherein the displacement of the bell-type countersink is a 3-axial movement on a linear path and/or a 5-axial movement on a curved path. The invention also relates to a bell-type countersink.