The complete cycle time was 35 hours-less than half the time that would have been needed using conventional methods-while the cost of milling was reduced by 45 percent.įor more information about Delcam Ltd., Windsor, Ontario, call (877) 335-2261 or visit For more information about Technicut Ltd., Sheffield, UK, e-mail or visit. (31.6”) Ti6Al4V titanium that is machined into a completed blisk with 31 blades, each 84mm (3.3”) in length with a root radius of 4mm (0.157”) and a scallop height of 10µm. This larger step-over means fewer cutting passes are needed to achieve the specified surface finish, significantly reducing machining time.Ī demonstration of the system, which can be seen on YouTube by entering /CTE-bliskvideo, begins with a billet of 804mm-dia. The tools incorporate a much larger radius on their cutting surfaces than the ballnose endmills that would normally be applied, enabling the barrel cutters to achieve the same cusp height with a step-over up to three or four times as large. In addition to the specific toolpaths for blisk machining in Delcam’s PowerMILL software, the key to the new method is the use of barrel cutters from Technicut for semifinishing and finishing. The lower sections are left in the rough state to maintain the stiffness of the blade in the area being machined and, therefore, minimize push off of the blade tip by the cutter. In addition to removing the bulk of the material between what will be the blades, roughing relieves any stresses in the billet introduced during the forging process.īoth the semifinishing and finishing operations on the individual blades are then undertaken in a series of vertical sections, working from the tip downwards. The initial roughing operation creates the blades with a series of slotting cuts using Technicut’s Titan X-Treme Ripper endmill. Blisks offer advantages in weight, operating efficiency and through-life servicing but are challenging to manufacture because of their highly complex shapes and the difficulty of machining the materials used, usually a titanium or nickel-base alloy.Īs with most machining projects, it comprises roughing, semifinishing and finishing. The blisk features blades and a disk as a single component, machined from a single piece of hard metal. The blisk has been an important turbo-engine component since it was introduced in the mid-1980s prior to that, a rotor disk with individually attached blades was used. PowerMILL image of a finishing operation on a blade barrel. Solutions for cost-effective, high-quality machining of HRSA blisks Blisks located on the cold compressor side of the engine are made of titanium, while the hot turbine side requires blisks made of heat-resistant super alloys (HRSA). Digital Manufacturing Softwareįurther details about the ModuleWorks 2022.04 release are available in the latest ModuleWorks YouTube videos: What’s New in ModuleWorks 2022.Autodesk CAM software developer Delcam Ltd., working with toolmaker Technicut Ltd., has created a software and cutting tool combination for machining blisks that reportedly reduces machining time and costs about 50 percent compared to traditional methods. The new stock-pillar-removal feature uses a spiral ramp motion to remove the pillar after the adaptive roughing cycle, thereby eliminating the vibrations and excessive heat to improve the cutting conditions and prolong the tool life. This pillar can create adverse cutting conditions such as vibrations and localized heat generation. The standard settings for adaptive roughing often leave a pillar at the center of the area being machined. Stock pillar removal for adaptive roughing The toolpath calculation algorithms use “out to in” ordering to remove the material gradually which enables the flatland cycle to machine parts with undercut features. This new option for the flatland cycle enables operators to machine flat undercut areas using slot milling tools.Īdditional toolpath slices are generated on the flat regions of the undercut. Operators can adjust the variable offset at different locations on the blade to fine-tune the toolpath according to measurement results based on the coordinate measuring machine, without changing the complex 3D file. Smooth toolpaths ensure consistent acceleration and, therefore, shorter cycle times. The new blisk module provides parameters and settings for creating very smooth toolpaths for multiblade machining. This is the first major ModuleWorks release of 2022 and contains new and enhanced features across the entire product range, including the new blisk module for multiblade machining, undercut machining with slot mills and stock pillar removal for adaptive roughing. ModuleWorks announces the release of its 2022.04 CAD/CAM software components for digital manufacturing.
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