Mesoscale fabrication of a complex surface for integral impeller blades

doi:10.1007/s11465-017-0426-1

Front. Mech. Eng.

2017, Vol. 12

Issue (1) : 116-131 https://doi.org/10.1007/s11465-017-0426-1

REVIEW ARTICLE

Mesoscale fabrication of a complex surface for integral impeller blades

Xibin WANG,Tianfeng ZHOU(

),Lijing XIE,Li JIAO,Zhibing LIU,Zhiqiang LIANG,Pei YAN

Key Laboratory of Fundamental Science for Advanced Machining, Beijing Institute of Technology, Beijing 100081, China

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Abstract

Integral impeller is the most important component of a mini-engine. However, the machining of a mesoscale impeller with a complex integral surface is difficult because of its compact size and high accuracy requirement. A mesoscale component is usually manufactured by milling. However, a conventional milling tool cannot meet the machining requirements because of its size and stiffness. For the fabrication of a complex integral impeller, a micro-ball-end mill is designed in accordance with the non-instantaneous-pole envelope principle and manufactured by grinding based on the profile model of the helical groove and the mathematical model of the cutting edge curve. Subsequently, fractal theory is applied to characterize the surface quality of the integral impeller. The fractal theory-based characterization shows that the completed mesoscale integral impeller exhibits a favorable performance in terms of mechanical properties and morphological accuracy.

Keywords mesoscale fabrication micro-milling tool mesoscale milling impeller blade

Corresponding Author(s): Tianfeng ZHOU

Just Accepted Date: 20 January 2017 Issue Date: 21 March 2017

Cite this article:

Xibin WANG,Tianfeng ZHOU,Lijing XIE, et al. Mesoscale fabrication of a complex surface for integral impeller blades[J]. Front. Mech. Eng., 2017, 12(1): 116-131.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-017-0426-1
https://academic.hep.com.cn/fme/EN/Y2017/V12/I1/116

Fig.1 Simplified model of the micro-end milling tool

Fig.2 Influences of the structural parameters on natural frequency. The influence of the tool bit diameter (

d t

) on the (a) first order, (b) second order, and (c) third order frequencies; the influence of the length-diameter ratio of the tool bit

R t

(

R t = L t / d t

) on the (d) first order, (e) second order, and (f) third order frequencies; the influence of the half-cone angle α on the (g) first order, (h) second order, and (i) third order frequencies

Tab.1 Geometric parameters of the micro-ball-end mill

Fig.3 Cutting edge curve of the micro-ball-end mill

Fig.4 Geometry of the micro-ball-end mill

Fig.5 Non-instantaneous center envelope principle for the grinding process: (a) Relative motion of the wheel and tool blank; (b) non-instantaneous center envelope

Fig.6 Projection drawings of the grinding wheel and the milling tool groove

Fig.7 Influences of the parameters of grinding wheel on the spiral grooved surface: (a) t₂=0, f₁=p/10, f₂=0, a=p/8; (b) t₂=1.5 mm, f₁=p/10, f₂=0, a=p/8; (c) t₂=1.5 mm, f₁=p/10, f₂=p/12, a=p/8; (d) t₂=1.5 mm, f₁=p/6, f₂=p/12, a=p/8; (e) t₂=1.5 mm, f₁=p/10, f₂=0, a=p/6; (f) t₂=0, f₁=p/10, f₂=0, a=p/6

Fig.8 Schematic of the grinding process of the rake face

Fig.9 Schematic of the grinding process of the primary clearance face

Fig.10 Orientation and position of the wheel in the workpiece coordinate system

Fig.11 Results of the grinding of the micro-ball-end mill: (a) End view; (b) side view

Tab.2 Preset and actual values of some of the tool parameters

Fig.12 Relationships of the forces in slot milling

Fig.13 Local details in micro-cutting

Fig.14 Cutting cycle in the milling process

Tab.3 Cutting parameters of the mesoscale integral impeller

Fig.15 Geometric model of the mesoscale integral impeller

Fig.16 Simulated machining process of the mesoscale integral impeller

Fig.17 Machined mesoscale integral impeller

Fig.18 Calculation process of the fractal characterization method

Fig.19 Morphology of the mesoscale integral impeller: (a) Machined blade; (b) machined hub

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