EDM as alternative to fir-tree profiling

ONA has carried out a study to analyse a wire electro-erosion process (WEDM) as an alternative to the conventional machining (broaching) of fir-tree profiles in discs for the aerospace sector.

In its research, ONA compared the EDM process with more conventional machining like broaching and milling. As key points in the research, ONA compared parameters such as the surface integrity requirements, precision and processing time of fir-tree machining. The test involved cutting a turbine disc with the following characteristics: Inconel 718 material; 350 mm outside diameter; 28 fir-tree slot profiles; slot profiles at 30°; 82 mm thick; profile tolerance of 0.01 mm; and fir-tree radial and angular positioning tolerance of 0.08 mm.
On completion of the tests, the results proved it possible to obtain a recast layer thickness in the necessary range (around 5 µm) and with sufficient precision in the fir-tree profile within a tolerance of 0.01 mm using WEDM technology. These results were obtained following one roughing pass and two finishing passes (three-cut strategy).
In worse flushing conditions (open nozzles), the material removal rate for roughing was 110 mm2/min. In fact, for the strategy used in the research (one pass for roughing and two passes for finishing), material removal rate was 60 mm2/min. On the other hand, in good flushing conditions (closed nozzles), a slight improvement in the material removal rate was observed; in the roughing process alone, it reached over 400 mm2/min.
Following the research, ONA concludes that WEDM machining of turbine disc fir-tree profiles is an extremely valid alternative to compete with broaching as an industrial solution in the aerospace sector. State-of-the-art and increasingly powerful generators, and more advanced numerical controls, allow for the optimisation of machining time and the reduction of white layer thickness.
For further information www.onaedm.com

New area sales manager at Open Mind

Growth at Open Mind Technologies has seen the CAM expert employ a new area sales manager.

Justin Talboys-Cotton has over 20 years’ experience in the manufacturing sector, starting his career as an automotive project manager overseeing all aspects of a cell, from SPC, ERP and quality management, to CAM implementation. Following success in this role, Talboys-Cotton joined a well-known CAM vendor
in a technical sales and business development position; demonstrating excellent sales results, account management and engineering expertise.
At Open Mind he will be responsible for servicing existing customers and developing new business across the Midlands region.
For further information www.openmind-tech.com

Radan partners with Russian laser machine specialist

CADCAM software expert Radan has developed a partnership with IPG IRE-Polus – a Russian division of IPG Photonics – which manufactures fibre laser machines.

The partnership provides for the new LaserCube precision flat-bed laser to be sold with the Radprofile module for programming, along with a special post-processor and set of macros. Moscow-based IPG IRE-Polus recently hosted a special training seminar on the software, conducted by an engineer from Dreambird, Radan’s official Russian and CIS distributor.
For further information www.radan.com

No delivery too challenging for XYZ

Having won a substantial six-machine order from Přibram Technical College in the Czech Republic, XYZ’s distributor Rexim had to overcome significant challenges to deliver the machines.

With careful negotiation, permission was granted to open up the inner and outer doorways, removing the door frames and cutting away brick and plasterwork to make the openings just large enough for the machines to pass through and remove. Adding to the challenge was the need to get the machines up a large flight of stairs between the outer and inner door, as well as negotiate a 90° corner. The stairs required a stage to be created on to which the machines were positioned before being slid through the door.
Preparation for the move took a total of 50 hours prior to the machines’ arrival, with just eight hours required to offload and locate the six machines, which comprised an XYZ 660 HD vertical machining centre, a CT 65 LTY turning centre, an SMX 3500 ProtoTrak mill, an SLX 355 ProTurn lathe and two manual training lathes. Once installed, a further 16 hours were needed to reinstate the doorways, work that involved 60 bags (25 kg each) of cement/plaster and two pallets of bricks.
For further information www.xyzmachinetools.com

50 years of Heidenhain (GB)

Established in Burgess Hill in 1969, Heidenhain (GB) Ltd, a wholly owned subsidiary of the German manufacturing group Dr Johannes Heidenhain GmbH, is this year celebrating 50 years of supporting industry.

Employing 24 people, the company is the sales, service and distribution centre for the UK and Ireland. Application engineering as well as customer service and support are also provided, covering the firm’s CNC systems, digital readouts, encoders, length gauges, measuring probes and machine calibration equipment.
A network of trained, regionally based distributors specialises in offering local sales and service of Heidenhain encoder products. All distributors are authorised, have exclusive access to the manufacturer’s technical databases, and are assisted as required by specialists in Burgess Hill. The test equipment they use is calibrated every two years.
For further information www.heidenhaingb.com