Modification of the 5-axis Toolpath to Increase the Turbine Hub Surface Quality

Abstract

This industrial article focuses on the finishing machining of workpieces made of aluminium alloy EN AW 7075 with a freeform shape, utilizing minimal material stocks. These workpieces are widely used in sectors like aviation and the energy industry. In these sectors, there is a pressing demand for high-quality production in the initial attempt, eliminating the need for subsequent post-processing operations. The reason for this is to save material and reduce production time. The paper, therefore, deals with a method that involves analysing the shape of a spherical end mill in relation to surface roughness and quality, followed by a mathematical recalculation of the tool path. This approach allows to adjust the machining settings during the preparation phase in order to achieve satisfactory surface quality across the entire machined surface. This method was successfully validated during the final surface treatment of the turbine hubs.