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Flank Milling optimisation


Objectives and content
Manufacturing of turbomachinery components can be
directly attributed to machining of complex geometries
like flow surfaces of compressor, fan and impeller
blades. These geometries are generally produced by point
milling. The main disadvantage of this process is that
point milling is a very time consuming process and that
it produces a scalloped surface finish. The height of
the scalloped ridges is directly related to the ball nose
radius and the number of cuts over the surface.
Therefore the industry emphasises a strong need for new
highly efficient technologies and software tools in order
to drastically reduce costs and through-put times to face
the heavy competition from outside the EU. An approach
to surmount the shortcomings of point milling by
simultaneously increasing the material removal rate,
eliminating necessary hand finishing processes and
assuring an improved component accuracy is to develop a
flexible and multifunctional machining technology and
CAM-software tool for 5-axis highly efficient surface
flank milling. The following advantages can be directly
attributed to the application of the flank milling
approach: approximately 14 times reduced number of cuts
over the surface correlating directly with necessary
machining time, higher material removal rates; a 100%
increase in machining of high temperature resistant
alloys can be achieved, improved surface quality
replacing lapping and polishing processes resulting in a
75% cost reduction, 5-times less consumption of tools
compared to point milling, reduction of tool wear; a
reduction of 20% using process adapted tool geometry and
assistances can be obtained. Based on the above given
explanations, the end-users estimate the potential cost
reduction due to productivity increase to roughly 2.17
million ECU per year. Additionally, a potential increase
of value added volume due to technology enhancements
would rise up to 132 KECU per year.
The consortium comprises of two important aeroengine
manufacturers, namely SNECMA and Rolls Royce, Norsk
Jetmotors which is a manufacturer of jet engine
components, Dassault Systems as the developer of one of
the most successful CAD/CAM-systems world-wide, CADE, a
developer of NCsimulation systems, Comau as an important
manufacturer of machine tools and IFW which has a strong
reputation in the research area.



Participants (5)

Dassault Systèmes SA
9,Quai Marcel Dassault 9
92156 Suresnes
Huron Graffenstaden
156,156 Route De Lyon
67400 Illkirch
Rolls Royce PLC
United Kingdom

BS12 7QE Filton
Schlo¯wender Strasse 5
30159 Hannover
dCade Gesellschaft für Produktionsinformatik mbH
25,Gustav-meyer-allee 25
13355 Berlin