Thermally neutral, the ECM/PECM processes can effectively machine the otherwise challenging-to-mill materials that comprise blades and blisks with no recast layer and minimal tool wear. The DC charge that crosses the electrolyte-flushed gap between the two causes the molecular erosion of the workpiece. Chomicz says ECM/PECM offers 10- to 30-percent faster cycle times than conventional five-axis machining of blades and blisks, does not create burrs, and achieves fine surface finishes to 0.05 Ra.īoth ECM and PECM remove metal through electrolysis, whereby the conductive workpiece is the positive anode and the tool is the negative cathode. This process combines an electrochemical machining (ECM) roughing operation and a precision electrochemical machining (PECM) finishing operation on the Emag PO 900 BF machine platform. However, Jonathan Chomicz, a technology specialist for German machine tool builder Emag, notes that an alternate, non-contact machining process can be more productive for these applications. Because of the extreme heat generated in the high-pressure compressor area of a turbine engine, these components are commonly manufactured from titanium or high-nickel-content alloys, such as Inconel.įive-axis machine tools are commonly used to rough and finish-machine blisks and blades. The second is a “blisk” design, in which a disk and its peripheral blade profiles are machined from a single billet of material. For this design, individual, contoured blades install around a disk’s periphery by fitting into precisely machined root-form slots. The first features separate disk and blade components. There are two primary compressor rotor designs for modern turbine engines.
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