A new method for 5-axis flank computer numerically controlled (CNC) machining is proposed. A set of tappered ball-end-mill tools (aka conical milling tools) is given as the input and the flank milling paths within user-defined tolerance are returned. Thespace of lines that admit tangential motion of an associated truncated cone along a general, doubly curved, free-form surface is explored. These lines serve as discrete positions of conical axes in 3D space. Spline surface fitting is used to generate a ruled surface that represents a single continuous sweep of a rigid conical milling tool. An optimization-based approach is then applied to globally minimize the error between the design surface and the conical envelope. The milling simulations are validated with physical experiments on two benchmark industrial datasets, reducing significantly the execution times while preserving or even reducing the milling error when compared to the state-of-the-art industrial software.

Manufacturing techniques that are applied to turbomachinery components represent a challenge in the aeronautic sector. These components require high resistant super-alloys in order to satisfy the extreme working conditions they have to support during their useful life. Besides, in the particular case of Integrally Bladed Rotors (IBR), usually present complex geometries that need to be roughed and finished by milling and grinding processes, respectively. In order to improve their manufacturing processes, Super Abrasive Machining (SAM) is presented as a solution because it combines the advantages of the use of grinding tools with milling feed rates. However, this innovative technique usually needed high tool rotary speed and pure cutting oils cooling. These issues implied that SAM technique was not feasible in conventional machining centers. In this work, these matters were tackled and the possibility of using SAM in these five-axis centers with emulsion coolants was achieved. To verify this approach, Inconel 718 single blades with non-ruled surfaces were manufactured with Flank-SAM technique and conventional milling process, analyzing cutting forces, surface roughness, and dimension accuracy in both cases. The results show that SAM implies a suitable, controllable, and predictable process to improve the manufacture of aeronautical critical components, such as IBR.

Manufacturing techniques applied to turbomachinery components represent a challenge in the aeronautical sector. These components are commonly composed of high resistant super-alloys; in order to satisfy the extreme working conditions, they have to support during their useful life. Besides, in the particular case of Integrally Bladed Rotors (IBR), they usually present complex geometries that need to be roughed and finished by milling and grinding processes, respectively. Thermoresistant superalloys present many challenges in terms of machinability what leads to find new alternatives to conventional manufacturing processes. In order to face this issue, this work presents a review of the last advances for IBR manufacturing and repairing processes.

Ball-burnishing is presented herein as a mechanical surface treatment for improving mechanical properties after the friction stir welding process. Ball-burnishing provides good surface finish, high compressive residual stresses, and a hardness increase of the surface layer. These characteristics are key for the fatigue life improvement of the component, and for wear resistance due to the higher hardness. This work presents a complete analysis of surface and sub-surface hardness values focusing on the determination of each process parameter influence. Burnishing pressure, radial width, and burnishing direction influence were analyzed. The tested material was 2050 aluminum alloy with two different heat treatments (T3 and T8). The optimum parameters were established, and a complete analysis of the surface hardness was performed. Results show that burnishing is an economical and feasible mechanical treatment for the quality improvement of component surfaces.