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Manufacturimg of comressor blade presentation 4 - copy

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anup sharma
anup sharma

The document discusses the manufacturing process of compressor blades. Compressor blades are used in aircraft propulsion systems and power stations. The process begins with selecting stainless steel as the raw material. The steel is cut to size and then milled and surface ground to shape. CNC machining is used to further refine the shape. Quality control checks the dimensions before polishing and packing. Compressor blades extract energy from high pressure gas and must withstand high stresses and loads during operation in propulsion and power generation systems.

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PRESENTATION TOPICS MANUFACTURING OF COMPRESSOR BLADE MEDHA COLLEGE OF ENGINEERING
AIM: The main aim of this project is to know about the processes involved in the manufacturing of the compressor blade. compressor blades are used in the propulsive system of an aircraft, thermal power stations and hydro-electric power stations. USED:
INTRODUCTION : A Compressor is a rotary mechanical device that extracts energy from a fluid flow and converts it into useful work. A Compressor is a turbo machine with at least one moving part called a rotor assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades so that they move and impart rotational energy to the rotor.
Compressor blade at working shaft
Raw Material: The raw material is the main source for the manufacturing of Compressor blade The raw material used in the manufacturing of Compressor blade is stainless steel. Specifications: The raw material cross-section is of Width= 170mm Height= 90mm
MAIN PROCESS INVOLED: • The design of the product, • The selection of raw materials and • The sequence of process through which the product will be manufactured. WHY UNCONVENTIONAL MACHINING COME INTO EXIST: • The hardness and strength of the material is very high(typically above 400HB) or the material is too brittle. • The work piece is too flexible, slender, or delicate to withstand the cutting or grinding forces, or the parts are difficult to fixture that is, to clamp in work holding devices.
• The shape of the part is complex, including such features as internal and external profiles or small diameter holes in fuel injection nozzles. • Surface finish and dimensional tolerance requirements are more rigorous than those obtained by other processes. • Temperature rise and residual stresses in the work piece are not desirable or acceptable.
MANUFACTURING PROCESS: Model designed OF COMPESSOR BLADE 1. Raw Material 2. Cutting 3. Milling 4. Surface Grinding 5. CNC Machining 6. Operations and Tools 7. Quality Control 8. Polishing 9. Vibro Tumbling
Cutting: Since the raw material is huge in length, it can not be directly taken to the process of manufacturing. So it is parted into number of pieces according to the blade profile requirement. The work piece required to obtain blade profile is of the following dimensions. Length= 265mm Width = 150mm Height= 90mm •After hacksaw cutting operation
Hacksaw Cutting Machine: The hacksaw machine is used for cutting the raw material. The work piece is held on the hacksaw machine with the help of chain pulley supported by three vertical members. Hacksaw Cutting Machine
Specifications: Hacksaw Blade Manufacturing : Power Axe Material : High Speed Steel(HSS) Length : 24inch Thichness : 1.9mm Motor RPM : 90 Spindle Power : 3HP Operation Time: 90min (for one work piece) Specifications: Hacksaw Blade Manufacturing : Power Axe Material : High Speed Steel(HSS) Length : 24inch Thickness : 1.9mm Motor RPM : 90 Spindle Power : 3HP Operation Time: 90min (for one work piece)
Work piece: Fig 4.5 Work Piece (While Cutting)
Milling: A milling machine is a machine tool used to machine solid materials. Milling machines are often classed in two basic forms •Horizontal milling machine, •Vertical milling machine, which refers to the orientation of the main spindle.
Surface Grinding: Surface grinding is used to produce a smooth finish on flat surfaces. It is a widely Used abrasive machining process in which a spinning wheel covered in rough particles (grinding wheel) cuts chips of metallic or non- metallic substance from a work piece, making a face of it flat or smooth.
Types of surface grinders: Horizontal-Spindle (peripheral) surface grinders: The periphery (flat edge) of the wheel is in contact with the work piece, producing the flat surface. Vertical-Spindle (wheel-face) grinders: The face of a wheel (cup, cylinder, disc, or segmental wheel) is used on the flat surface. Disc grinders and double-disc grinders: Disc grinding is similar to surface grinding, but with a larger contact area between disc and work piece.
Material After Grinding
CNC Machining: (COMPUTERISED NUMERICAL CONTROLLED MACHINE) CNC refers to the automation of machine tools that are operated by preprogrammed commands encoded on a storage medium.
2) COLLETS: Collets are used for holding the tool in the adaptor. Collets are flexible to allow tools of different diameters to fit in to it. Collets are characterized by the range of diameters which can be hold by using the collets. They contain different slots as shown in figure to provide a secure positioning of cutter in it . They also capable of absorbing the vibrations produced during the machining. 3) FIXTURES: Fixtures are used to hold the specimen during operation. Once the specimen has fixed into the fixture it won’t be removed till the end of the operation. Fixtures can be of various shapes it has to be ensured that it can hold the specimen carefully till the end of the operation. It’s shape varies with the shape of the specimen to be fixed and the operating procedure.
Quality Control: Visual Inspection In visual inspection we check the length, thickness and width of the given specimen at the corresponding sections. We need to check the given specimen, whether it will meet the requirements of our design or not. By using the venire calipers we calculate the basic dimensions of the specimen. OBJECTS USED IN VISUAL INSPECTION: • Height Gauge: It is used to measure the height of the specimen from the datum surface and to measure the groove and slots. To check the depth of the slot and the height of the slot by this measuring gauge. The readings of the height are shown digitally on the display arranged on the gauge.
Magnetic V-block: The specimen is placed on the V-block and then required measurements are taken, marking the specimen is also done in this process Blade measuring gauge: This apparatus is used to measure the final shape of the blade profile Cleaning and Packing: After the completion of the final inspection, the Compressor blade is proceeded into the next stage of cleaning. In cleaning the blade is rinsed with the water and the water is wiped with the cotton cloth. Polishing: ROUGH POLISHING: Rough polishing includes removal of any irregular shapes from the surface of the profile. We use ball cutter for rough machining
CONCLUSION The processes involved in the manufacturing of the Compressor blade was studied. These blades are responsible for extracting energy from the high temperature and high pressure gas produced by the combustor. As these blades work mostly at high temperatures and pressures, they were designed to withstand high stresses and loads. compressor blades are used in the propulsive system of an aircraft, thermal power stations and hydro-electric power stations.
FINAL VIEW OF COMRESSOR BLADE
THANKS

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Manufacturimg of comressor blade presentation 4 - copy

  • 1. PRESENTATION TOPICS MANUFACTURING OF COMPRESSOR BLADE MEDHA COLLEGE OF ENGINEERING
  • 2. AIM: The main aim of this project is to know about the processes involved in the manufacturing of the compressor blade. compressor blades are used in the propulsive system of an aircraft, thermal power stations and hydro-electric power stations. USED:
  • 3. INTRODUCTION : A Compressor is a rotary mechanical device that extracts energy from a fluid flow and converts it into useful work. A Compressor is a turbo machine with at least one moving part called a rotor assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades so that they move and impart rotational energy to the rotor.
  • 4. Compressor blade at working shaft
  • 5. Raw Material: The raw material is the main source for the manufacturing of Compressor blade The raw material used in the manufacturing of Compressor blade is stainless steel. Specifications: The raw material cross-section is of Width= 170mm Height= 90mm
  • 6. MAIN PROCESS INVOLED: • The design of the product, • The selection of raw materials and • The sequence of process through which the product will be manufactured. WHY UNCONVENTIONAL MACHINING COME INTO EXIST: • The hardness and strength of the material is very high(typically above 400HB) or the material is too brittle. • The work piece is too flexible, slender, or delicate to withstand the cutting or grinding forces, or the parts are difficult to fixture that is, to clamp in work holding devices.
  • 7. • The shape of the part is complex, including such features as internal and external profiles or small diameter holes in fuel injection nozzles. • Surface finish and dimensional tolerance requirements are more rigorous than those obtained by other processes. • Temperature rise and residual stresses in the work piece are not desirable or acceptable.
  • 8. MANUFACTURING PROCESS: Model designed OF COMPESSOR BLADE 1. Raw Material 2. Cutting 3. Milling 4. Surface Grinding 5. CNC Machining 6. Operations and Tools 7. Quality Control 8. Polishing 9. Vibro Tumbling
  • 9. Cutting: Since the raw material is huge in length, it can not be directly taken to the process of manufacturing. So it is parted into number of pieces according to the blade profile requirement. The work piece required to obtain blade profile is of the following dimensions. Length= 265mm Width = 150mm Height= 90mm •After hacksaw cutting operation
  • 10. Hacksaw Cutting Machine: The hacksaw machine is used for cutting the raw material. The work piece is held on the hacksaw machine with the help of chain pulley supported by three vertical members. Hacksaw Cutting Machine
  • 11. Specifications: Hacksaw Blade Manufacturing : Power Axe Material : High Speed Steel(HSS) Length : 24inch Thichness : 1.9mm Motor RPM : 90 Spindle Power : 3HP Operation Time: 90min (for one work piece) Specifications: Hacksaw Blade Manufacturing : Power Axe Material : High Speed Steel(HSS) Length : 24inch Thickness : 1.9mm Motor RPM : 90 Spindle Power : 3HP Operation Time: 90min (for one work piece)
  • 12. Work piece: Fig 4.5 Work Piece (While Cutting)
  • 13. Milling: A milling machine is a machine tool used to machine solid materials. Milling machines are often classed in two basic forms •Horizontal milling machine, •Vertical milling machine, which refers to the orientation of the main spindle.
  • 14. Surface Grinding: Surface grinding is used to produce a smooth finish on flat surfaces. It is a widely Used abrasive machining process in which a spinning wheel covered in rough particles (grinding wheel) cuts chips of metallic or non- metallic substance from a work piece, making a face of it flat or smooth.
  • 15. Types of surface grinders: Horizontal-Spindle (peripheral) surface grinders: The periphery (flat edge) of the wheel is in contact with the work piece, producing the flat surface. Vertical-Spindle (wheel-face) grinders: The face of a wheel (cup, cylinder, disc, or segmental wheel) is used on the flat surface. Disc grinders and double-disc grinders: Disc grinding is similar to surface grinding, but with a larger contact area between disc and work piece.
  • 17. CNC Machining: (COMPUTERISED NUMERICAL CONTROLLED MACHINE) CNC refers to the automation of machine tools that are operated by preprogrammed commands encoded on a storage medium.
  • 18. 2) COLLETS: Collets are used for holding the tool in the adaptor. Collets are flexible to allow tools of different diameters to fit in to it. Collets are characterized by the range of diameters which can be hold by using the collets. They contain different slots as shown in figure to provide a secure positioning of cutter in it . They also capable of absorbing the vibrations produced during the machining. 3) FIXTURES: Fixtures are used to hold the specimen during operation. Once the specimen has fixed into the fixture it won’t be removed till the end of the operation. Fixtures can be of various shapes it has to be ensured that it can hold the specimen carefully till the end of the operation. It’s shape varies with the shape of the specimen to be fixed and the operating procedure.
  • 19. Quality Control: Visual Inspection In visual inspection we check the length, thickness and width of the given specimen at the corresponding sections. We need to check the given specimen, whether it will meet the requirements of our design or not. By using the venire calipers we calculate the basic dimensions of the specimen. OBJECTS USED IN VISUAL INSPECTION: • Height Gauge: It is used to measure the height of the specimen from the datum surface and to measure the groove and slots. To check the depth of the slot and the height of the slot by this measuring gauge. The readings of the height are shown digitally on the display arranged on the gauge.
  • 20. Magnetic V-block: The specimen is placed on the V-block and then required measurements are taken, marking the specimen is also done in this process Blade measuring gauge: This apparatus is used to measure the final shape of the blade profile Cleaning and Packing: After the completion of the final inspection, the Compressor blade is proceeded into the next stage of cleaning. In cleaning the blade is rinsed with the water and the water is wiped with the cotton cloth. Polishing: ROUGH POLISHING: Rough polishing includes removal of any irregular shapes from the surface of the profile. We use ball cutter for rough machining
  • 21. CONCLUSION The processes involved in the manufacturing of the Compressor blade was studied. These blades are responsible for extracting energy from the high temperature and high pressure gas produced by the combustor. As these blades work mostly at high temperatures and pressures, they were designed to withstand high stresses and loads. compressor blades are used in the propulsive system of an aircraft, thermal power stations and hydro-electric power stations.
  • 22. FINAL VIEW OF COMRESSOR BLADE