High-performance milling of turbine blades

More economical machining of turbine blades requires special types of machines, and it is necessary to combine high-performance milling, high-precision 3D machining, and space freeform machining. The precise contour of each blade can be guaranteed.

Turbine blades up to 500 mm in length are typically obtained by milling the bars. The high-strength steel is first machined to ensure that the profile of the blade from the root to the head facilitates subsequent finishing.

For the above high-performance milling, Hamel's HSTM 5-axis turning and milling center from Meeder near Coburg is used in conjunction with the electric spindle, which can make full use of the existing cutting material production capacity. Smooth machining requires a stable machine structure, especially with a flexible mass distribution to ensure excellent dynamic stiffness.

For high-performance milling, the HSTM Series 5-axis turning and milling center is used in conjunction with the electric spindle to match existing cutting materials.

Powerful electric spindle

The electric motor with a standard power of 54 kW can work with the HSK A63 tool holder and a standard magazine with a capacity of 24 tools. A magazine of 36 to 60 capacities is also available. A fully automatic tool management mode is available depending on customer requirements. In addition, each tool is equipped with an electronic chip that stores clear tool identification information and its own contour data. The parameters of each tool can be automatically read and transferred to the machine by means of an electronic read/write head. With the life management tool, you can ensure that each tool works exactly in accordance with its design life, ensuring high machining results.

Finishing of the blade freeform surface requires compliance with optimal cutting conditions to achieve the desired profile and to provide a consistent machining allowance for subsequent polishing operations. The spindle speed can be up to 16,000 rpm, allowing the tool to work in the smallest diameter area in accordance with the optimum cutting conditions.

Next, the feed trajectory of the guide rail must strictly follow the calculation results to ensure that the required turbine blade profile curve is obtained according to the calculated action coefficient. The difficulty in the contour curve lies in the entry and exit areas, so high angular acceleration is required to ensure ideal milling. A high-performance torque motor can be used on the tool's rotating shaft and maintain a good dynamic relationship with the fluid-powered pivot bearing. In addition, when machining longer length blades, an active rotating shaft can be provided on the tailstock at the other end to overcome the deformation caused by milling.

Automated tooling system requires integration with Fanuc's M-710i series of 6-axis crank robots

The synergy between the three linear axes (X, Y, Z) and the two rotating axes (A, B) is important for machining free-form surfaces with high fit accuracy requirements. Therefore, a drive system requiring high dynamic performance and a high-performance control system capable of operating in the millisecond range can provide accurate information to the drive system. Hamuel has extensive experience with Siemens' 840D system and Fanuc's 31i-A5 system.

Unmanned production

The automated tooling system requires the integration of Fanuc's M-710i series of 6-axis crank robots (Fig. 2), and Hamuel has successfully implemented its work with the HSTM 300 series. A 24-capacity chain magazine can be used when the workpiece is heavy. In the above two schemes, the operator must place the blank on the workpiece holder at the preparation station and then automatically feed it to the processing station. The workpiece holder is automatically engaged with the system via the HSK 100B type interface for quick clamping of the workpiece.

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