A twisted turbine blade with a rough surface is continuously being polished on a CNC machine. Under precise control, the sand belt meticulously smooths the entire blade, leaving no corners untouched.
**Gas Compressor Blade Grinding**
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Do not underestimate this process—smooth blades play a vital role in the performance of aeroengines. The precision achieved through this technology ensures better efficiency and reliability.
This machine has broken foreign technological monopolies, offering advanced tools for manufacturing nuclear power components, gas turbines, and aeroengines in China.
Liu Shusheng, General Manager of Hongji CNC Equipment Co., Ltd., explained that complex curved surfaces on blades are critical to power plants like steam turbines and aeroengines. Their geometric accuracy and surface quality directly impact equipment efficiency and safe operation.
The "Key Blades for Complex Machining of Six-axis Linkage Numerical Control Belt Grinding Mill Key Technology Research and Application" project developed by Beijing Shengwei Hongji and others has made significant strides in independent innovation. This six-axis linkage NC grinding machine solves technical challenges in blade finishing and breaks foreign monopolies. It has been applied in nuclear turbine and aircraft engine blade manufacturing, becoming essential for high-quality blade production. The project won first prize at the 2016 Beijing Science and Technology Awards.
Manual polishing has become a bottleneck in blade development. In many cases, it's time-consuming, inefficient, and harmful to workers due to dust exposure. The manual process often results in inconsistent finishes, affecting the aerodynamics and overall performance of engines.
For large blades, such as those used in nuclear power plants, manual polishing is extremely challenging. These blades are massive, complex, and require high precision. Manual methods struggle to maintain consistency, which can affect thermal efficiency and operational safety.
On the other hand, small aero-engine blades, though tiny, are equally demanding. Their thin profiles and complex geometries make them prone to damage during manual polishing. Any error can lead to performance issues or even failure.
To address these challenges, Liu Shusheng and his team set out to develop a six-axis linkage CNC grinding machine. They faced the challenge of programming and developing specialized software, but eventually succeeded in creating an advanced system capable of precise, automated blade finishing.
The machine uses multi-belt devices and micro-contact force control to achieve ultra-precise grinding, meeting the strict requirements of aeroengine blades. It can polish even the thinnest parts with minimal error, surpassing existing foreign technologies.
Since its launch, the six-axis CNC belt grinder has gained widespread use across China, from nuclear turbine blade manufacturing to new aircraft engine production. The demand has far exceeded supply, highlighting its importance in modern manufacturing.
Companies like Dongfang Steam Turbine and Wuxi Turbine Blade have seen a dramatic improvement in blade quality and consistency. One notable example is the CAP1400 PWR nuclear unit, where the need for dynamic balancing was significantly reduced after using the CNC machine.
Beyond nuclear and aerospace applications, the technology has also supported the development of new aero-engines, helicopter blades, and propellers, providing advanced manufacturing solutions.
Looking ahead, Liu Shusheng believes that with smart manufacturing, 3D printing, and precision casting, the future of CNC technology is bright. His team is already working on next-generation machines, aiming to stay at the forefront of innovation.
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