Productivity enhancement of aircraft turbine disk using a two-step strategy based on tool-path planning and NC-code optimization

Most of the parts of an aircraft require the use of lightweight and high-strength materials. Since aircraft parts mainly use mechanical cutting processes, which are the most suitable material removal mechanism, to minimize changes in material properties, it is necessary to develop an optimal cutting tool and cutting solution for each material. This work aims to enhance productivity and reduce the production cost of an aircraft turbine disk through designing a cutting strategy and optimizing the cutting conditions using a simulation approach. The number of tools was reduced from eight to six compared to the existing process conditions for semi-finishing and finishing of a turbine disk, and a new tool path was proposed through simulation. The cycle time was reduced by about 24%. NC-code optimization was performed through feed-rate optimization considering cutting force and chip thickness. As a result, cycle times were reduced by about 14%. Through tool-path optimization and NC-code optimization, it was confirmed that the total cycle time was reduced by about 54%, and tool wear was significantly improved.