A Quality Prediction and Parameter Optimization Approach for Turbine Blade Multistage Manufacturing

As core components of an aircraft engine, turbine blades are featured by complex curved surface with strict precision requirements in multistage manufacturing processes (MMPs). Hence, reliable quality prediction and parameter optimization strategy on MMPs have long been in great demand. However, most techniques focus on the precision improving of single-stage single-product manufacturing systems; these improvements are difficult to implement in MMPs with coordinate transformations among multiple machines. In this article, we propose a noninvasive feature-based quality prediction and parameter optimization framework for high-precision MMPs. In particular, rather than retrofitting sensors onto machinery after installation, this study presents an executable and noninvasive solution by using coordinate measuring machine (CMM) data as input features for prediction. Based on features of different stages of machining, a sequential multistep deep learning architecture is developed to predict the final product quality. A preheating optimization algorithm, modified from a local gradient search method, is used for the optimization of key initial machining features, which results are further improved by the L-BFGS method, thus increasing the final production quality. To estimate the effectiveness of the proposed framework, experiments are carried out on two series of aviation turbine blades with complex curved surfaces from the Wuxi Turbine Blade Company Ltd. China. CMM data at key stages (i.e., blade root milling and comprehensive accurate milling) are used as inputs to predict the final geometrical errors. Comparison results verify that the proposed framework achieves the smallest root mean square error at 0.030 mm and 0.032 mm for two blades, respectively.