![]() During the process, the workpiece becomes the positive anode and the tool the negative cathode as an electrolyte solution flows between them. With their PECM technology, the experts from EMAG ECM have further developed this method and tuned it to perfection. PECM - Non-contact material removal and fast processes.Įlectro-chemical machining is a well established process for machining extremely hard materials. Machining from single Turbine Blades to the Complete Blisk Precise PECM technology and EMAG high performance components are naturally available in both types.īoth these machines also provide the user with key EMAG innovations such as a Mineralit® polymer concrete machine base, intelligent software and hardware interfaces and efficient automation solutions. The systems differ in machining area size, footprints, generator capacity and the number of machining axes. Productive milling of blisks is based on three pillars: a high-velocity multi-axis machine tool, advanced CNC and CAD/CAM software, and not least efficient milling cutters, all working in concert to achieve considerably reduced cost per unit (CPU).Īndrei Petrilin is application/project engineer, milling manager, with Iscar.EMAG ECM has two machine types for the different machining tasks of jet engine and turbine production: while the small PO 100 SF model is designed for machining turbine blades, the larger PO 900 BF machines complete blisks. For these situations, it’s recommended to use solid carbide tapered ball nose endmills, which are characterized by different helix angles of the endmill flutes. The cutting tool often works with a high overhang that raises the requirement of the tool’s stability. When finish milling of blisks, a high-quality surface finish and predictable long tool life are vital. In some blisk rough slot milling situations, such as the machining of Ni-alloys, the trochoidal technique is the most productive machining method, therefore, a trochoidal tool path is highly recommended.įor these applications, solid carbide endmills with multiple flutes with different helix angles, like Iscar’s Chatterfree tools, enable high stock removal rates. A range of shanks are available and are made from steel for general-duty applications, tungsten carbide with greater rigidity and heavy-metal for increased vibration resistance. If necessary, the assembly can be extended by the use of extensions. The benefits of a flexible system like this include minimum setup time and the ability to configure the system in more than 15,000 ways from standard shanks and heads. These tools are preferred where a slot to be milled is deep and narrow, and they are also ideal for milling fillet areas. MULTI-MASTER end milling tools consist of a shank carrying interchangeable solid carbide cutting heads that are treaded to allow a quick-change connection with the shank. Using premium submicron and ultra-fine carbide substrates, which in combination with nano-layer PVD coating technology and post-coating SUMO TEC treatment, improve the tools’ impact strength and wear resistance, resulting in longer tool life and enhanced working characteristics.Īs the milling of blisks begins with rough slot milling, solid carbide endmills are specifically designed for this demanding operation. Major cutting tool suppliers to the global aerospace manufacturing industry develop a wide range of milling cutters to ensure the premium quality of blisks and also boost users’ productivity.Īn Iscar solution for the efficient production of blisks is provided by its coated solid carbide endmills and its MULTI-MASTER tools. Usually, blisks are produced from titanium (Ti) or nickel-based alloys (Ni-alloys), therefore the milling cutters used need to meet the stringent productive and fail-safe machining requirements of these hard-to-cut materials. Naturally, such machining demands effective and reliable cutting tools.Īs the majority of blisk machining consists of milling, the quality of the milling cutters used is of paramount importance. The use of blisks in the compressors and fans of modern turbojet engines not only leads to gains in performance, it negates the need to assemble the rotor disc and blades and also allows the vital component to be produced in a single setup on the same machine tool.ĭue to their complicated shapes, the machining of blisks requires the use of multi-axis machine tools and advanced CNC software. Also known as integrally bladed rotors (IBR’s), blisks are usually machined from a solid piece of material. Since their introduction in the mid-eighties, the use of blisks continues to grow in popularity. A blisk (bladed disk) is an aero-engine component consisting of a rotor disk and multiple blades in a single part.
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