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© WZL/Fraunhofer IPT
EDM and ECM processes for turbine engine manufacture Proposal for STC E Keynote 2014
Fritz Klocke, Andreas Klink WZL, RWTH Aachen University, Germany
Hongkong, 24th August 2012
Seite 2 © WZL/Fraunhofer IPT
Motivation I/II
Quelle: Siemens, AgieCharmilles, Leistritz, MTU, WZL
ED
M
EC
M
Blade cutting W-EDM 3D ring structures, seal slots + cooling holes by S-EDM GE Blue Arc™ blisk machining
Blade production by ECM Curved cooling holes by ECM ECF Blisk production by ECM
Seite 3 © WZL/Fraunhofer IPT
Motivation II/II
Quelle: KUL, IHI
Goal: Discussion on reachable …
Geometries
Material Removal Rates
Surface Integrity
in comparison to other machining technologies (cutting, grinding, Laser)
µ-E
DM
ED
M-C
oatin
g
Production of ceramic micro turbine via µ-EDM MS Coating and built-up technology
Seite 4 © WZL/Fraunhofer IPT
Preliminary Outline Introduction and Motivation
Electro Discharge Machining (EDM) for turbine manufacture – Sinking EDM – Wire EDM – Arc machining (GE)
Electrochemical Machining (ECM) for turbine manufacture – Sinking ECM 3D – Cooling holes
Further EDM-ECM processes for turbine manufacture – Process combinations (EDM + ECM) – ECM-Grinding – Electropolishing – Micro turbines – Surface treatment (IHI)
Machine tools and CAD-CAM aspects
Seite 5 © WZL/Fraunhofer IPT
6-axis-Sinking-EDM of radial compressor stage Rough machining: Turning
EDM of inflow and outflow sides
Finishing: Polishing
Quelle: sm-weber
Seite 6 © WZL/Fraunhofer IPT
EDM in turbine manufacture
Quelle: Mühlbauer: Funkenerosion im Triebwerksbau, MTU, 2011
Seite 7 © WZL/Fraunhofer IPT
ECM blade and blisk production
ECM blade machining
ECM blisk machining
Compressor blade
Guide blade
Quelle: Leistritz Turbomaschinen Technik GmbH
Seite 8 © WZL/Fraunhofer IPT
Titanium blisk produced via ECM
Quelle: MTU-Aero Engines
Zweiteilige Elektroden
Titanblisk
Werkstoff:Vorschub:Titanbasislegierung1,5 mm/min
Spannung:Strom:13 V15000 A
Seite 9 © WZL/Fraunhofer IPT
ECM and PECM Economic alternative
to milling
On the way to serial production
Blisk of nickel-based alloys
Very low efforts to smooth surface
Quelle: www.mtu.de/report, EMAG
Seite 10 © WZL/Fraunhofer IPT
ECM of curved cooling holes Principle
Application
Quelle: Rolls-Royce, Köppern
Seite 11 © WZL/Fraunhofer IPT
EDM, ECF and STEM production of cooling holes
Quelle: P. Thümmler, Herstellung von komplexen Kühlluftbohrungen in Hochdruckturbinenschaufeln, MTU, 2008
1th generation EDM
2nd generation Laser
Seite 12 © WZL/Fraunhofer IPT
Electrochemical Fine Drilling ECF Material:
Nickel-based alloys
61 holes in one step
Length: 10 mm
Diameter: 0,5 mm
Quelle: MTU
Seite 13 © WZL/Fraunhofer IPT
Comparison of different manufacturing processes for cooling holes
Quelle: P. Thümmler, Herstellung von komplexen Kühlluftbohrungen in Hochdruckturbinenschaufeln, MTU, 2008
Seite 14 © WZL/Fraunhofer IPT
GE Blue Arc™ blisk machining 3 times of
material removal rate increase, 65% cutter cost reduction and 30% energy saving when applied to Inco718 as compared with conventional machining.
A video can be bound on youtube.
Quelle: B. Wei; A. Trimmer; Y. Luo; R. Yuan; S. Hayashi; M. Lamphere: Advancement in High Speed Electro-Erosion Processes for Machining Tough Metals, ISEM 2010
Seite 15 © WZL/Fraunhofer IPT
MSCoating for Aircraft Engine Parts Micro Sparc Coating
Coating and cladding technology
Replace plating, welding and plasma spraying
Quelle: http://www.ihi.co.jp/msc/
Seite 16 © WZL/Fraunhofer IPT
Technological + economical comparison of blisk roughing strategies
Seite 17 © WZL/Fraunhofer IPT
Surface integrity comparison grinding – Wire-EDM Ground specimen
Eroded specimen
Crack path in an eroded specimen
500 µm
Thermally
influenced zone
Cracks
Material
break out
Deformed grains
Continously
thermally
influenced zone
Cracks
Thermally
induced marks,
shaped like shells
Crack path
Crack step
Black marks
Seite 18 © WZL/Fraunhofer IPT
ECM machine tools
Machine framework: Polymer concrete MINERALIT®
Machine tool housing: stainless steel
Workpiece diameter up to 900 mm
Workpiece weight max. 500 kg
High positioning accuracy
Precise and flexible programmable oszillator
Grafic Visualisation
Scalable generator technology up to 30.000 A
Pulse frequency up to 100 kHz
Complex filtration
Quelle: EMAG ECM
Seite 19 © WZL/Fraunhofer IPT
To be discussed … Literature
– Only 60 – 80 scientific papers expected…
– …but a lot of information from the industry could be available.
– Industry oriented KN like STC G 2009: „Industrial challenges in grinding“
Support from industry (corporate members) !?! – Pratt Whitney, AgieCharmilles, ExtrudeHone, … – RR, GE, MTU, Siemens, Leistritz, Mitsubishi, EMAG, …
Authors and Co-authors – F. Klocke, A. Klink (WZL) – …
Seite 20 © WZL/Fraunhofer IPT
Thank you for your kind attention!
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