A twisted engine blade with a rough surface is continuously being polished on a CNC machine. Under the precise control of the CNC system, the sand belt smoothly grinds the entire blade, even reaching the most challenging areas that were previously impossible to access.
Gas compressor blade grinding
Commercial high pressure compressor blades R1.5 blade root grinding effect
Don't underestimate this process—smooth blades play a vital role in the performance of aeroengines. The precision and quality of these components directly impact efficiency, safety, and longevity of power systems.
This advanced machine has broken the foreign technology monopoly, offering cutting-edge solutions for China’s nuclear power, gas turbine, and aeroengine industries. It's not just a tool; it's a breakthrough that supports national technological independence.
Liu Shusheng, General Manager of Hongji CNC Equipment Co., Ltd., explained that complex curved surfaces on blades are critical in power plants like steam turbines, gas turbines, and aeroengines. Their geometric accuracy and surface quality directly affect energy conversion efficiency and the safe operation of power machinery.
The project "Key Blades for Complex Machining of Six-axis Linkage Numerical Control Belt Grinding Mill Key Technology Research and Application," developed by Beijing Shengwei Hongji CNC Equipment Co., Ltd., has achieved independent intellectual property rights through research and development. This six-axis blade linkage NC grinding machine and programming system solves the technical challenges in finishing complex blade surfaces and breaks foreign monopolies. Its applications have expanded into nuclear turbine blade manufacturing and new aircraft engine blade production, becoming essential tools for high-quality blade manufacturing.
Manual polishing has become a major bottleneck in blade development. While the equipment manufacturing industry is the cornerstone of national construction, the turbine power plant manufacturing technology is a symbol of a strong country. The blade, as a key component, determines the efficiency and performance of the entire system.
"The higher the surface finish of the working blade, the better. Surface quality and consistency directly affect the energy conversion efficiency of the equipment," Liu said.
Multi-axis linkage CNC machines are essential for processing turbine blades in nuclear and thermal power plants. These blades are complex thin-walled parts with free-form surfaces and large curvature changes, making them difficult to finish using traditional methods.
As energy sources grow more powerful, blades need to be more curved, twisted, and swept to achieve better aerodynamics and maximize power per unit volume. However, manual polishing remains inefficient, unsafe, and inconsistent, leading to quality issues and affecting engine performance.
"Manual polishing can destroy the precise surface created by five-axis milling," Liu warned. The mismatch between advanced five-axis milling and manual polishing has become a major obstacle in blade manufacturing, especially for large nuclear blades and small aero-engine blades.
For large nuclear blades, the size and complexity make manual polishing increasingly difficult, affecting flow and thermal efficiency. For small aero-engine blades, their delicate structure makes manual polishing prone to damage and inconsistency, which directly impacts engine performance.
To overcome these challenges, Liu and his team developed a six-axis linkage CNC grinding machine, breaking the foreign monopoly. They faced significant difficulties, including developing specialized software for programming and controlling the machine's motion path and grinding pressure.
Through innovative programming algorithms and a custom six-axis CNC system, they achieved automatic programming and processing. This advancement allowed for high-efficiency, high-precision grinding of complex blade surfaces, surpassing existing foreign technologies.
Today, China's independently developed six-axis linkage CNC grinding belt machine is widely used across the country, supporting both nuclear and aeroengine blade manufacturing. The demand far exceeds supply, proving its value in the market.
Companies like Dongfang Steam Turbine and Wuxi Turbine Blade have seen significant improvements in blade quality and consistency. Even international experts were surprised by the precision achieved through these machines.
Looking ahead, Liu is confident that with smart manufacturing, 3D printing, and precision casting, new CNC machines will continue to lead the industry, maintaining China's technological edge.
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