Robotization of process of electric-discharge machining of holes in high pressure turbine blades

Abstract

This investigation provides problems of electrical discharge machining within aero-engine manufacturing industry. Common issues in serial process are significant tool-electrode wear, forming the recast layer, changing geometry of tool side surface and relatively low process performance. Among these the relatively low performance is the most economically significant. An automation of electrical discharge machining using a robotic complex is proposed applying five electrical discharge machine tools including die-sinking machine and hole drilling machine. The optimal configuration is based on simulation modelling results aiming most equal load ratio across machine tools. Machine tools were selected based on requirements for productivity and accuracy. A system of quick-release automated fastening and a system for linear displacement of the manipulator robot were developed to service the machine tools. Designed robotic complex has a significant increased productivity and reduced requiring number of production stuff needed for five machine tools.