Adaptive Drilling of Film Cooling Holes of Turbine Vanes Based on Registration of Point Clouds
Xue-Cheng Xi, Jian Wang, Si-Meng Zhu, Jie-Yu Ma, Wansheng Zhao
Abstract
The manufacture of film cooling holes on turbine guide vanes of an aeroengine suffers from the contour errors resulting from a casting process. It is therefore necessary to adjust positions and orientations of cooling holes for each vane. This article proposes an adaptive compensation machining method based on a combination of a principal component analysis (PCA) iterative closest point (PCA-ICP) registration method and an orthocenter mapping method. First, a registration is carried out between an ideal point cloud and a measured point cloud by a laser measurement machine to obtain a transformation matrix. Then, the exit center of a cooling hole is obtained by an orthocenter mapping method. Simulation results show that the machining errors of vanes can be improved from <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$\pm$</tex-math></inline-formula> 0.1 to <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$\pm$</tex-math></inline-formula> 0.03 mm. Machining tests show that with a combination of the PCA-ICP registration and orthocenter mapping methods, cooling holes can be drilled adaptively to meet the machining requirements.