Compensation of part distortion in process design for re-contouring processes

The repair of compressor blades requires a precise coordination of the material deposit and the subsequent re-contouring process. Since re-contouring is the last step in the process chain, it is a crucial stage for the final part quality and shape. Therefore, machining-induced part distortions must be considered in process design. This paper introduces a method for the simulation-based compensation of part distortions. The method combines process planning and evaluation by means of a geometric simulation. In order to validate the approach, milling experiments are carried out. A subsequent measurement of the part distortion can be replaced by up to 21% using the present approach.