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Unconventional (Advanced) Manufacturing Processes for Gas-Engine Turbine Components

Objective

In the project ADMAP-GAS new Unconventional Advanced Manufacturing Processes for Gas-Engine Turbine Components will be developed in order to substitute the critical conventional broaching process for fir tree profiles between rotating blades and disks. Therefore the two manufacturing technolgies “High Speed Wire-EDM Broaching” and “Abrasive Water Jet Broaching” – W² - will be developed, optimised and evaluated highlighting their individual performance and effectiveness for the machining task. High material removal rates and highest surface finishing will be achieved resulting in an equal or even better workpiece performance. By using these two unconventional manufacturing technologies with their inherent advantages a much higher technological and time based flexibility in production of fir tree profiles can be achieved. Failure risks and machining costs will be drastically decreased due to faster and more efficient machining in combination with a higher degree of automation. Tool wear and time consuming tool renewal can be avoided. Machine tool footprints (in comparison to conventional horizontal broaching centers) or machine heights and fundaments (vertical centers) will be drastically reduced. Energy consumption will be reduced and environment will be preserved. ADMAP-GAS addresses the relevance to the call by the “development of techniques for increased flexible tooling” for the manufacture of gas turbine components. The W² technologies will also enable the application of innovative and light weight design concepts (more complex shapes, tighter tolerances, etc.) for the turbine components that were not possible due to the technical limitations of the broaching process. This will additionally result in reduced production costs across the whole production cycles. Production waste and consumables will be minimised. A high degree of automation and faster machining times will result in a highly effective machining process with virtually no failure risk.

Field of science

  • /engineering and technology/environmental engineering/energy and fuels/fossil energy/gas
  • /social sciences/sociology/industrial relations/automation

Call for proposal

FP7-AAT-2008-RTD-1
See other projects for this call

Funding Scheme

CP-FP - Small or medium-scale focused research project

Coordinator

RHEINISCH-WESTFAELISCHE TECHNISCHE HOCHSCHULE AACHEN
Address
Templergraben 55
52062 Aachen
Germany
Activity type
Higher or Secondary Education Establishments
EU contribution
€ 517 320
Administrative Contact
Drazen Veselovac (Mr.)

Participants (7)

DIAD SRL
Italy
EU contribution
€ 385 656
Address
Strada Della Praia 12/C
10090 Buttigliera Alta
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Sonia Sereno (Dr.)
AGIE CHARMILLES NEW TECHNOLOGIES SA
Switzerland
EU contribution
€ 576 347
Address
Rue Du Pre De La Fontaine 8
1242 Meyrin
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Roberto Perez (Dr.)
OELHELD GMBH
Germany
EU contribution
€ 257 040
Address
Ulmer Strasse 135-139
70188 Stuttgart
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Manfred Storr (Dr.)
Berkenhoff GmbH
Germany
EU contribution
€ 205 800
Address
Berkenhoffstraße 14
35452 Heuchelheim
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Thomas Wagner
TEKS SARL
France
EU contribution
€ 403 757
Address
Rue Du Praya, Les Toits Blancs 23
05100 Montgenevre
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Sarah Kleeman (Dr.)
ADVANCED MANUFACTURING (SHEFFIELD)LIMITED
United Kingdom
EU contribution
€ 237 573
Address
Club Mill Road
S6 2FH Sheffield
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Gareth Morgan (Dr.)
THE UNIVERSITY OF SHEFFIELD
United Kingdom
EU contribution
€ 300 164
Address
Firth Court Western Bank
S10 2TN Sheffield
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Gill Wells (Dr.)