Physics-based design for an impeller machining process

This paper presents a machining process design approach that uses physics-based modeling and optimization to result in an efficient machining strategy to manufacture a titanium impeller. Material properties of the workpiece are used to guide process parameter selection, and FEA analysis of chip formation is performed to ensure the chosen tooling and process parameters to avoid tool failure. An industry-representative impeller was designed and then machined on a 5-axis machine tool to demonstrate the success of the approach. The modeling, optimization, approach is outlined, demonstration results are presented, and future machining process development approaches are proposed. By using modeling to select tooling and process parameters by ensuring peak tool temperatures and stresses are below allowable limits, the process was redesigned to reduce cycle time by over 50%.