Surface Roughness of Aircraft Engine Blade Models Produced with Various Methods of Rapid Prototyping

Results of the study of surface roughness of the aircraft engine blade model, produced with various methods of rapid prototyping are presented. Blade models were made with two incremental methods of rapid prototyping: stereo lithography (SLA-250 device) and three-dimensional printing (Z510 Spectrum printer). In incremental methods of rapid prototyping a model is formed by hardening of consecutive layers of the base material. Model position in the equipment work area has a significant influence on surfaces quality of a prototype, especially in stereo lithography method. It is essential in case of elements with curvilinear surfaces like aircraft engine blades. A CAD blade has been exported to the STL format within surface precision of 0,001 mm. Afterwards, it was duplicated and set up in various positions of the virtual work area of the 3D Light year programme dedicated to the SLA-250 device. Data prepared in this way have been used for producing physical models. Roughness surveys were carried out with the Talyscan150 device, manufactured by Taylor Hobson Precision. The measurements permitted making three-dimensional maps of surfaces of blade prototypes. Thanks to that, it was possible to determine optimum position of blade in the work area of RP devices in respect to prototype surface quality.