Digital process chain: Scientific based manufacturing of an intake fan blisk prototype

The manufacturing of prototype components for engine rotors demands the highest standards of the manufacturing processes used, machine tool programming and process design. On the one hand, process chains are often used due to the small number of components required, which differ considerably from series production. On the other hand, the processes used are not optimized for productivity in the context of series production. A special challenge in the process chain is the machining of the airfoil / the flow geometry of the component while carrying out as less iterations as possible for process design, as these are associated with high costs for the required raw parts and tools. According to the current state of the art, machine programming and process design in the manufacturing of blisk prototypes is almost experienced based. This paper presents and describes a digitized process chain that was used to manufacture an intake fan blisk prototype for rig application using no spare part for process design and CAM program validation. It was used just one raw part for machining the final prototype. The content focuses on the scientific methods used throughout the entire manufacturing process development cycle, specially over the process design and machining up to quality assurance.