Tech Focus: EDM Wire EDM machine for turbine disc fir-tree roots

Editor:
Steffen Donath

The AV35 goals to be one in every of ONA’s most bold initiatives in recent times: It represents their technological growth of WEDM expertise utilized to the manufacture of extremely demanding elements.

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The most commonly used machining techniques to manufacture turbine disc fir-tree roots have traditionally been physical machining processes: Broaching, grinding and milling.
Probably the most generally used machining strategies to fabricate turbine disc fir-tree roots have historically been bodily machining processes: Broaching, grinding and milling.

(Supply: Ona)

The corporate explains that one in every of its nice virtues is that it’s a normal machine. It has a primary construction to which modules/equipment will be added relying on the kind of element to be manufactured. This permits for absolutely automated machining. Simply change or adapt a few of these parts to fabricate several types of elements.

Considered one of ONA’s biggest challenges has been to develop EDM expertise tailored to the method with the intention to convert electrical discharge machining right into a aggressive and high-quality machining course of, even when in comparison with a number of the commonest processes within the trade, equivalent to milling or broaching. An instance of the latter is the slicing of fir-tree roots for aviation turbine discs, primarily manufactured by broaching. A profitable challenge to spotlight is the work carried out in collaboration with an organization within the aeronautics trade. This was a challenge through which ONA manufactured fir-tree roots for aviation generators on the ONA AV35 wire-cutting EDM machine (WEDM).

Based on the corporate, there are presently few alternate options in the marketplace to the AV35. What distinguishes the ONA AV35 from different EDM machines for the manufacture of fir-tree roots for turbine discs, is that the ONA AV35 is a normal machine to which equipment/modules will be added, which makes it in a position to adapt to the manufacture of different elements. In different phrases, this gear is just not manufactured completely for one function.

A few of AV35’s accent objects embody:

  • Contact probe; to make sure the right positioning of the half.
  • Script programming; instrument for the creation of sensible ‘in-process’ measurement applications.
  • 2-axis rotary desk with pneumatic chuck. Automated and repetitive clamping of the half; it allows the erosion of the half in a single bundle.
  • Full half traceability and course of evaluation due to the ONA Sensible Join platform; possibility to observe the machining of every part of the half, carry out statistics, forestall errors, foresee upkeep duties, hint the elements, and so forth.
  • Automation of the entire course of; final part: A robotic has been added to maintain the machine working day and night time with the identical accuracy.

“Probably the most difficult half was coordinating with totally different departments in addition to with the consumer. The machine was designed based on the particular wants of the purchasers. We had to make use of state-of-the-art software program instruments to adjust to the traceability necessities,” one in every of ONA’s technicians describes the method

The AV35 gives vital benefits to firms, equivalent to a decrease preliminary funding in equipment, due to this adaptability, and extra autonomy. The whole machining course of is automated and managed in order that the half meets the necessities set out: The continual monitoring of the supplied information ensures progress is being made based on the preliminary programming. Within the occasion of an error (a change in water temperature, and so forth.), a warning sign is emitted.

Know-how on the stage of broaching and milling

Discs are crucial rotating elements in a gasoline turbine: They attain as much as 60,000 revolutions per minute and should be capable of stand up to excessive temperatures and stress fluctuations, whereas being light-weight and secure. The standard of the fabric used (normally nickel-based superalloys) and the machining course of (excessive geometrical and floor high quality necessities) are subsequently important. Probably the most generally used machining strategies to fabricate turbine disc fir-tree roots have historically been bodily machining processes: Broaching, grinding and milling. Broaching being, maybe, the very best recognized and most used course of.

With regard to electrical discharge machining, the event of recent turbines has been the principle drive that has made EDM a viable and aggressive manufacturing course of for the manufacture of elements within the aeronautics trade. The principle benefits of growing new EDM turbines are: The capability to offer a better energy output, thus growing productiveness; and the variation of the expertise and machining technique to scale back the warmth affected zone in addition to the white layer, that are indispensable, particularly within the aeronautics trade. ONA’s WEDM course of additionally gives turbine producers higher flexibility when it comes to deadlines and references: It permits them to adapt sooner than typical machining processes would enable them to.

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