Features of post-machining methods of micro turbojet engine structural elements at CNC machines in accordance with the existing state of development of production facilities

Cover Page


Cite item

Full Text

Open Access Open Access
Restricted Access Access granted
Restricted Access Subscription or Fee Access

Abstract

BACKGROUND: The production of complex aircraft engine parts, such as compressor and turbine wheels, using traditional machining methods is a labor-intensive and time-consuming process. Technological limitations, such as temperature deformations and the need for subsequent high-precision machining of critical surfaces, arise when using additive technologies for their manufacturing.

AIM: Development and justification of an integrated design and technological approach to the production of compressor and turbine wheels of a micro turbojet engine combining additive technologies and mechanical post-machining.

METHODS: The study examines structural elements to compensate for negative temperature effects, special supporting structures, elements for subsequent precise datum setting at a computer numerically controlled five-axis machine, allowances for post-machining. In addition, the study shows the technology of post- machining, including the preparation of machining datum surfaces on a universal machine, CAD preparation of the machining project, selection of tools, tooling and cutting modes, machining the final shape of the blades at a five-axis milling machine.

RESULTS: An integrated approach including design and technological solutions has been developed. A comparison of the labor intensity of the proposed and traditional production methods is carried out, showing a reduction in manufacturing time. Quantitative results of roughness measurement on critical surfaces after finishing are presented.

CONCLUSION: The practical value of the study lies in proving the applicability and effectiveness of the developed approach for the mass production of complex aircraft engine parts. The completed study and proposed solutions make it possible to overcome the key limitations of additive technologies and to ensure the manufacturing of products with high quality and precision properties.

Full Text

Restricted Access

About the authors

Anton V. Pobelyanskiy

Baltic State Technical University “VOENMEH” named after D.F. Ustinov

Email: pobelyanskiy@inbox.ru
ORCID iD: 0009-0003-0492-5879
SPIN-code: 4369-7020

Head of Additive Technologies and Volumetric Scanning Center

Russian Federation, Saint-Petersburg

Dmitriy K. Dmitriev

Baltic State Technical University “VOENMEH” named after D.F. Ustinov

Email: Dima21021998@yandex.ru
ORCID iD: 0009-0006-1012-3372
SPIN-code: 2788-4700

Lecturer of Engines and Power Plants of Aircraft Department

Russian Federation, Saint-Petersburg

Marina V. Vilkina

Baltic State Technical University “VOENMEH” named after D.F. Ustinov

Email: m.vilkina@mail.ru
ORCID iD: 0009-0005-5796-4198
SPIN-code: 1532-4820

Lecturer of Technology and Production of Artillery Armaments Department

Russian Federation, Saint-Petersburg

Artyom A. Levikhin

Baltic State Technical University “VOENMEH” named after D.F. Ustinov

Email: levikhin_aa@voenmeh.ru
ORCID iD: 0000-0001-8231-2179
SPIN-code: 3891-7890

Cand. Sci. (Engineering), assistant professor, Head of Engines and Power Plants of Aircraft Department

Russian Federation, Saint-Petersburg

Andrey A. Shirokikh

Peter the Great St. Petersburg Polytechnic University

Author for correspondence.
Email: andreyka-29@mail.ru
ORCID iD: 0009-0006-7621-0778
SPIN-code: 8501-4351

Engineer of the Higher School of Power Engineering

Russian Federation, Saint Petersburg

References

  1. Aeronet [internet] Accessed: 10.08.2025. Available from: https://nti2035.ru/markets/aeronet
  2. Ekimov AI, Kutakhov VP, Plyaskota SI. Promising areas of development of unmanned aircraft technology. Proceedings of the Russian Academy of Rocket and Artillery Sciences. 2016(2):104–112. (In Russ.) EDN: WGYDMR
  3. Pobelyansky AV. Additive technologies in rocket and space technology. In: Scientific readings in memory of Academician V. P. Glushko. The first All-Russian scientific and practical conference. Ser. “Library of the journal “Voenmeh. Bulletin of BSTU”” 2020:42–48. (In Russ.) EDN: XSNLUC
  4. Meinhard TS. Gas Turbine Design, Components and System Design Integration. Springer; 2018. doi: 10.1007/978-3-319-58378-5
  5. Dmitriev DK, Pobelyansky AV. Consideration of the effect of engine micro-dimensionality on the efficiency of blade machines of micro-sized GTE. In the collection: YOUTH. technic. space. Proceedings of the twelfth All-Russian Youth Scientific and Technical Conference, 4 vols. Ser. “Library of the journal “Voenmeh. Bulletin of BSTU. Saint Petersburg; 2020;67:191–195. (In Russ.) EDN: ZJLIGI
  6. Pobelyansky AV, Dmitriev DK, Levikhin AA. Intensification of convective heat transfer of the walls of the heat pipe of a 3D-printed microdimensional turbojet engine. Omsk Scientific Bulletin. A series of aviation, rocket and power engineering. 2022;6(1):128–138. doi: 10.25206/2588-0373-2022-6-1-128-138 (In Russ.) EDN: QKFEAB
  7. Kumar J, Nair CGK. Current Trends of Additive Manufacturing in the Aerospace Industry. Advances in 3D-Printing & Additive Manufacturing Technologies. 2017:39–54. doi: 10.1007/978-981-10-0812-2_4
  8. Pobelyansky AV, Levikhin AA. Investigation of the possibilities of additive technologies in the creation of elements of propulsion systems. In: Additive technologies: present and future. Collection of reports of the vi international conference. Moscow; 2020:19–36. (In Russ.) EDN: MSSQQW
  9. Wohlers Report 2019: 3D Printing and Additive Manufacturing State of the Industry. Wohlers Associates. 2019. doi: 10.1007/978-981-10-0812-2_4
  10. Theoretical foundations and practical implementation of technological processes for manufacturing engine parts and assemblies of unmanned aerial vehicles using additive technologies: research report (final, Stage II). BSTU “VOENMEH” named after D.F. Ustinov; Levikhin AA, Pobelyansky AV, Pinchuk VA, et al. Saint Petersburg; 2019. No. GR AAAA19-1190113090101-4. Translated by No. N-141.M-A8-8513.2.2019
  11. Maharramova LA, Scissnitskiy YuA, Volkov SA, et al. Prospects of using additive technologies to create parts and assemblies of aviation gas turbine engines and ramjet engines. Bulletin of Samara University. Aerospace engineering, technology, and mechanical engineering. 2019;18(3):81–98. doi: 10.18287/2541-7533-2019-18-3-81-98 (In Russ.) EDN: KSPTDD
  12. Kulemin VYu. Approaches to assessing complexity in the creation of products of a high degree of technological complexity of weapons, military and special equipment based on digital twins. Proceedings of the Russian Academy of Rocket and Artillery Sciences. 2023(3):98–103. (In Russ.) EDN: OPAZXL
  13. Chen L, He Y, Yang Y, et al. The research status and development trend of additive manufacturing technology. The International Journal of Advanced Manufacturing Technology. 2017;89(9–12):3651–3660. doi: 10.1007/s00170-016-9335-4 EDN: SNZDZF
  14. Burakov AV, Perminov AS, Galerkin YuB, et al. Application of 3D printing technology to increase the efficiency of low-consumption centrifugal compressors. In the book: Technique and technology of petrochemical and oil and gas production. In: Proceedings of the 10th International Scientific and Technical Conference. 2020:88–89.
  15. Burakov AV, Levikhin AA, Pobelyansky AV, Perminov AS. Adaptation of 3D printing technology and topological optimization methods for creating low-consumption turbochargers. Omsk Scientific Bulletin. A series of aviation, rocket and power engineering. 2020;4(2):72–84. doi: 10.25206/2588-0373-2020-4-2-72-84 (In Russ.) EDN: AZDWYQ
  16. Bezlyazyniy VF, Fedoseev DV. Analysis of surface roughness parameters of blanks obtained by the method of additive technologies. High-tech technologies in mechanical engineering. 2019(12):3–11. doi: 10.30987/2223-4608-2019-2019-12-3-11 (In Russ.) EDN: AWGQQF

Supplementary files

Supplementary Files
Action
1. JATS XML
Download
2. Fig. 1. Compressor wheel of a micro turbojet engine.

Download (217KB)
Indexing metadata
3. Fig. 2. The process of machining compressor wheels after additive manufacturing: a, compressor wheel after additive manufacturing, with allowances; b, superimposition of the electronic model of the compressor wheel before and after turning machining of the base; c, superimposition of the electronic model of the compressor wheel before and after blade milling.

Download (224KB)
Indexing metadata
4. Fig. 3. Turbine wheel of a micro turbojet engine.

Download (171KB)
Indexing metadata
5. Fig. 4. Datum setting of the compressor wheel of a micro turbojet engine.

Download (180KB)
Indexing metadata
6. Fig. 5. Photos of compressor wheel after additive manufacturing and after machining at a universal lathe.

Download (189KB)
Indexing metadata
7. Fig. 6. Obtaining machining datum surfaces of the compressor wheel at a universal lathe: a, unfolding the central hole; b, machining of the base.

Download (254KB)
Indexing metadata
8. Fig. 7. Obtaining machining datum surfaces of the turbine wheel at a universal lathe: a, removing the additional supports; b, unfolding the central hole; c, disk surface machining.

Download (431KB)
Indexing metadata
9. Fig. 8. Preparation of the project for the compressor wheel and the turbine wheel.

Download (304KB)
Indexing metadata
10. Fig. 9. Compressor wheel and turbine wheel after blades machining at a five-axis machine.

Download (191KB)
Indexing metadata

Copyright (c) 2026 Eco-Vector

License URL: https://eco-vector.com/for_authors.php#07