{"id":5237,"date":"2025-01-10T15:04:36","date_gmt":"2025-01-10T07:04:36","guid":{"rendered":"https:\/\/turbineblade.net\/?p=5237"},"modified":"2025-01-10T15:04:37","modified_gmt":"2025-01-10T07:04:37","slug":"research-and-application-of-adaptive-machining-technology-for-damage-repair-of-aero-engine-turbine-blade-tips","status":"publish","type":"post","link":"https:\/\/turbineblade.net\/de\/research-and-application-of-adaptive-machining-technology-for-damage-repair-of-aero-engine-turbine-blade-tips\/","title":{"rendered":"Research and application of adaptive machining technology for damage repair of aero-engine turbine blade tips"},"content":{"rendered":"

The repair of damaged turbine blades<\/a> is of great significance to the maintenance and life extension of aircraft engines. This paper reviews the research progress of the repair technology of a certain nickel-based cast high-temperature alloy turbine working blade, focusing on the repair method of adaptive machining at the blade tip, and deeply expounds the experimental processing process and verification results, and looks forward to the development prospects of turbine blade repair technology.<\/p>

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The aircraft engine is the power core of the aircraft. Among the various components of the aircraft engine, the functional mission and working characteristics of the turbine blades determine that it is one of the rotating parts with the worst stress and the largest load in the aircraft engine, which also causes the common failure and damage of the turbine blades. Among them, crack failure has the highest probability of occurrence and the greatest harm, mainly fatigue cracks caused by centrifugal force superimposed on bending stress, flutter fatigue cracks caused by vibration environment, and high-temperature fatigue cracks caused by corrosion damage caused by environmental media. At this stage, in order to reduce the cost of engine use, the remanufacturing and repair of damaged turbine blades is of great significance.<\/p>

Among the key technologies for turbine blade repair, adaptive processing technology has attracted the attention of many researchers as an effective means to achieve smooth overlap of damaged boundaries and high-precision forming of repaired areas. TTL, a British company, obtains information on blade cross-section lines through contact measurement methods and uses the measured cross-section line profile information to complete the model reconstruction of the tip wear area by offsetting along the Z direction, and generates processing codes to remove the cladding layer. Delcam, a British company, proposed a model reconstruction method for turbine blade tip repair by on-machine measurement, which reduced the problem of positioning error accumulation through on-machine measurement; two cross-sectional data near the cladding layer were obtained by contact measurement, and the geometric model to be repaired of the worn blade tip of the straight-grained blade was calculated, so as to complete the entire repair process by grinding. Based on the grey system theory, Ding Huapeng predicted the arc line and thickness of the blade profile in the damaged area, and then reconstructed the complete blade model, and then obtained the repair defect model through Boolean difference, thereby achieving a certain repair effect. Hou F et al. proposed an adaptive repair method for blade body, including welding surface modeling and optimization modeling of the target repair surface, and finally used simulation to prove the effectiveness of the repair method. Zhang X et al. proposed an automated repair scheme for damaged areas of engine blades, which is directly formed by material cladding. Compared with traditional repair methods, it is innovative to a certain extent, but it is difficult to repair turbine blades with complex surfaces.<\/p>

The above research shows that aircraft engine blade repair is a hot topic in the aviation field at home and abroad. In the field of repair machining, the focus is on achieving smooth overlap between the repair area and the non-damaged area, as well as high-precision forming after repair. Therefore, based on the above repair research, this paper takes the damaged turbine working blade as an example to carry out the application research of adaptive machining technology for blade tip damage repair, ensuring that the machining area and non-machining area of \u200b\u200bthe repaired blade can achieve smooth transition overlap, and the overall repair surface meets the final tolerance requirements of the repaired blade.<\/p>

1 Analysis of the processability of blade tip damage repair<\/strong><\/h2>

Figure 1 shows a typical turbine blade tip crack defect. Based on this, a method for remanufacturing and repairing the damaged blade tip of an aircraft engine turbine blade is proposed. A remanufacturing and repair solution is established, which includes removing the damaged part of the blade tip – molten welding and depositing solder (as shown in Figure 2) – acquiring blade point cloud – reconstructing the blade digital model – adaptive processing of the blade, to achieve adaptive repair of the blade geometric size accuracy and performance recovery. The quality and performance of the repaired blade meet the design requirements and can be used for real-time repair at the repair site, providing an effective solution for realizing batch repair processing of damaged components of aircraft engines.<\/p>

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