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Development of tomorrow's High-tech Broaching Technology for aircraft turbines and power units

Objective



Objectives and content
Cost effective and ecologically compatible machining
processes for key components of both aircraft turbines
and fixed turbines for power units are urgently needed in
order to strengthen the competitiveness of these
important European industrial branches.
New high-temperature alloys allow higher combustion
temperatures and an increase in efficiency leading to a
reduction of fuel consumption and pollution. But it is
well known that high-temperature alloys used for turbine
and power plant components are difficult to machine.
One of the key processes in turbine manufacturing is
broaching. This process is best suited for manufacturing
high precision and complex shape slots in turbine disks,
used to fasten the blades. But broaching of hightemperature alloys can be done up to now only at a very
low cutting speed of about 2 - 5 m/min. The tools used
are made from high-speed-steel (HSS), which is less wearresistant and more temperature sensitive than other
cutting materials like cemented carbides, cermets etc..
Cooling lubricants therefore have to be used, increasing
costs in manufacturing and creating problems like
pollution, health risks for the operators etc...
The main objective of the HIBROTEC project is the
development of a high-performance broaching technology
comprising all properties of these safety-relevant
components made from difficult-to-machine materials.
Claimed innovative aspects of this proposal include:
Development of the high-performance broaching
technology by application of new, economic tool concepts
(assembled tools, tools using indexable inserts, graded
boundary layers, tool composites)
Application of highly-wear-resistant cutting materials
and coatings (cemented carbides, micro-grain carbides,
cermets, titanium-based coatings, multilayer coatings,
solid lubricants)
High productivity through high cutting speeds in
industrial production (increased by a factor of 10 - 20
as compared to today's industrial standard)
Environmental orientated machining without cooling
lubricants respectively with minimal quantity
lubrication.
The structure of the consortium comprises all relevant
disciplines and embraces all the elements needed to
design 'tomorrow's high-tech broaching technology' for
aircraft turbines and fixed turbines for power units.
Within the proposed project, the knowledge and the
experience of a cutting tool manufacturer (BöHLERIT) a
coating specialist (HAUZER) and a broaching tool and
broaching machine manufacturer (VARINELLI) will be
combined to create a ,'tooling and machining system'
aimed at developing broaching technology for high
temperature alloys. Cutting technology, dry and
minimised lubrication machining will be developed and
optimised by WZL. The industrial relevance will be
demonstrated by the industrial endusers in this
consortium in a wide range of applications for aircraft
turbine components made from nickel-based alloys and
fixed turbines for power unit components made from highalloyed steel materials (BMW ROLLS-ROYCE, FIAT AVIO,
ROLLS-ROYCE, SIEMENS KWU).

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

Officine Meccaniche Varinelli SpA
Address
46,Via Del Bruno
20043 Arcore
Italy

Participants (7)

AACHEN UNIVERSITY OF TECHNOLOGY
Germany
Address
53 B,steinbachstraße 53 B
52056 Aachen
BMW Rolls-Royce GmbH - Aeroengines
Germany
Address
60-70,Hohemarkstrasse
61440 Oberursel
Böhlerit Ges.m.b.H. & Co. KG
Austria
Address
Werk Vi Strasse
8605 Kapfenberg
Fiat Avio SpA
Italy
Address
312,Via Nizza
10127 Torino
Hauzer Coating Centrum BV
Netherlands
Address
22,Groethofstraat
5916 PB Venlo
ROLLS ROYCE PLC
United Kingdom
Address
Filton
BS12 7QG Bristol
Siemens AG
Germany
Address
12-16,Hattenstrasse
10553 Berlin