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PLM-based Digital Design Manufacturing and Process Monitoring of an Impeller Manufacturing – A Senior Project at Virginia State University

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2015 ASEE Annual Conference & Exposition


Seattle, Washington

Publication Date

June 14, 2015

Start Date

June 14, 2015

End Date

June 17, 2015





Conference Session

Best Practices and Lessons Learned in Capstone Design Projects

Tagged Division


Page Count


Page Numbers

26.1229.1 - 26.1229.18



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Paper Authors


Zhenhua Wu Virginia State University

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Dr. Zhenhua Wu, is currently an Assistant Professor at Virginia State University. He received his PhD in Mechanical Engineering from Texas A&M University. His current research interests focus on control and diagnose complex systems, sustainable manufacturing, adaptive machining, and nano manufacturing.

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Nasser Ghariban Virginia State University

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PLM Based Digital Design Manufacturing and Process Monitoring of the Impeller Manufacturing- A Senior Project at XXXXX XXX UniversityXXXXXX University’s manufacturing program is surrounded by the industrial/research communitiesincluding Rolls-Royce, Alstom, Newport News Ship Building, and Commonwealth Center for AdvancedManufacturing etc. Impellers, as advanced mechanical products commonly used in turbo-machineries, areheavily investigated by these companies on design, manufacturing and inspection. An impeller consists ofnumbers of similar blades revolving at 360 degrees onto a hub surface. Each blade is ruled surface andtwisted from the leading edge to the trailing edge. The blades consist of suction surface, pressure surface,leading edge, trailing edge and shroud surface. Due to the design complexity of impellers, 5-axis CNCmachines are the most suitable for machining impellers because of the flexibility of tool orientations thatis a necessary to machine the area between the twisted blades. 5-axis machines are capable to produce ahigh quality impeller. However, they are too expensive for many universities or industries. 3-axis CNCmachines are efficient on cutting time and cost, although serious collision will occur due to the toolmovement that constraint only to translations movement. Thus, integrating 3-axis for rough machiningand 5-axis for finish machining could be an economic way of fabricating impellers. Besides this, XXXrecently received a generous NX PLM (Product Life Management) gift from Siemens. Equipping ourstudents with skills of “Digital Design Manufacturing and Process Monitoring of the ImpellerManufacturing” will better prepare them for job market or graduate schools.With those in mind, two groups of students are assigned different senior design tasks. Students in Group Idesign impeller using PLM’s CAD capability, then simulate the machining process and generate the NCcode for impeller using PLM’s CAM capability, then select cutting tools and cutting parameters, finallymanufacturing the impeller with 3-Axis and 5-Axis CNC machines. Group II’s task is to monitor cuttingforce, power consumption during the manufacturing process. Their tasks involves with sensor selection,Labview programming to integrate sensors, data collection and analysis on force and power on differentmachining features on impeller. Group II is also required to implement finite element analysis on themachining and fixture to simulate the strength and force response using PLM’s CAE capability. Thispaper details the challenges, solutions and outcomes of this senior project. The learning outcome fromthis project can improve the curriculum of 1) CAD/CAM, 2) Manufacturing Processes, and 3)Automation etc.

Wu, Z., & Ghariban, N. (2015, June), PLM-based Digital Design Manufacturing and Process Monitoring of an Impeller Manufacturing – A Senior Project at Virginia State University Paper presented at 2015 ASEE Annual Conference & Exposition, Seattle, Washington. 10.18260/p.24566

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