Design and development of a five-axis machine tool with high accuracy, stiffness and efficiency for aero-engine casing manufacturing

• Published in: Chinese journal of aeronautics 2022-04, Vol.35 (4), p.485-496
• Main Authors: WANG, Yutian, WANG, Dong, ZHANG, Shizhen, TANG, Zihan, WANG, Liping, LIU, Yanmin
• Format: Article
• Language: English
• Subjects: Aero-engine casing manufacturing; Compact motorized spindle; Dual drive swing head; Five-axis machine tool; Supporting stiffness
• ISSN: 1000-9361
• DOI: 10.1016/j.cja.2021.04.001

In order to satisfy the machining requirements of aero-engine casing in modern aviation industry, this paper investigates three main issues during the design and development process of a five-axis machine tool with high accuracy, stiffness and efficiency, including whole structure design, key components design, and supporting stiffness design. First, an appropriate structure of five-axis machine tool is determined considering the processing characteristics of aero-engine casing. Then, a dual drive swing head and a compact motorized spindle are designed with enough drive capability and stiffness, and related structure, assembly method, cooling technology, and performance simulation are given in detail. Next, a design method of supporting stiffness of guide is proposed through the deformation prediction of the spindle end. Based on above work, a prototype of machine tool is developed, and some experiments are carried out, including performance tests of swing head and motorized spindle, and machining of a simulated workpiece of aero-engine casing. All experimental results show that the machine tool has satisfactory accuracy, stiffness and efficiency, which meets the machining requirements of aero-engine casing. The main work can be used as references for engineers and technicians, which are meaningful in practice.