EDMmatter_Header_8.18.16

Drilling Pre-Coated Blades and Vanes for Turbine Engine Components Just Got Easier

facebooktwittergoogle_pluslinkedinfacebooktwittergoogle_pluslinkedin

Jet engines have the ability to produce additional power when the combustion gases entering the turbine are superheated. However, there are limits to the amount of heat the blade materials can take—in fact, for each 10°C rise in temperature of the metal, the blade life is cut in half.

EDMmatters_Pic2_8.18.16

To minimize hot spots during operation and to improve jet engine performance, designers increase the number of cooling holes on blades to channel the air, and include complex geometries in these holes for improved airflow. Aerospace manufacturers also introduce new materials and coatings that can withstand extreme heat. While these specs enable engines to operate at higher temperatures, they can also present challenges for traditional hole drilling methods.

Now there’s a new system that aerospace manufacturers are using to make it easier to precisely drill pre-coated blades and vanes for turbine engine components. It combines laser-cutting technology guided by a water jet with advanced, high-speed electrical discharge machining (EDM) in an automated cell.

Synova’s Laser MicroJet® MCS-500 series of 3- and 5-axis cutting machines along with Makino’s EDBV3 and EDBV8 EDM hole-drilling machines have been combined in an automated cell to process pre-coated blade or vane detail. The laser system cuts the diffuser shapes in the coating layer using a hair-thin water jet, and the EDM is used to drill the through holes. The EDBV system has an innovative solution to handle difficult-to-image “non-line-of-sight” holes. A sophisticated data-transfer scheme is also part of the cell, enabling high-accuracy hole drilling on both machines to produce complete components.

EDMmatters_Pic1_8.18.16

Combining these machines in an automated cell leverages the technologies of each machine to deliver a superior hole-drilling solution. The unique combination of machining processes gives manufacturers new capabilities to produce pre-coated turbine engine components with exacting details that achieve near-perfect levels of engineered cooling airflow.

Learn more about this combined laser and EDM process at booth S-8700 at IMTS 2016.

Read Article

Join the conversation.

Your email address will not be published.

Tech Tips: Automatic Wire Threading Settings – Part 3

facebooktwittergoogle_pluslinkedinfacebooktwittergoogle_pluslinkedin

Are you aware of the AWT (Automatic Wire Threading) functions that can be accessed from the AWT page located on the MAINTENANCE screen?  Below are some details on the most commonly used functions, and settings from this screen can be saved and loaded as an NC program at any time.

EDMmatters 8-4-16

  • M6 Search After Fail: When this function is activated, the machine will automatically move to the next M6 wire thread position within the program when the AWT process is unsuccessful. This function prevents the loss of unattended machine time by allowing the machine to skip a part/cavity feature and continue machining when the AWT process fails at a start location.
  • Submerged AWT: Enables submerged AWT up to the set height limit, which will help to reduce the total cycle time required for the AWT process.
  • AWT Position Search: This function is used to automatically move the X/Y axes in a grid pattern to find a point where the machine can successfully perform an AWT process. This is especially useful in preventing lost production due to a start hole being off location, and settings can be changed to control the total grid movement amount. Once a successful AWT start location is determined, machining begins and the axes return to the original zero programmed start location and normal processing begins.
  • Non-Contact Search M17: This function is used to eliminate a contact point between the wire and the workpiece, which will prevent the machine from starting. This is especially helpful when threading in small diameter start holes that might not be perfectly straight or on location, and is activated by the M17 command in the NC program. This function enables the machine to move in the X/Y/U/V axes to eliminate a contact between the wire and workpiece, and settings can be changed to control the total movement amount. Once a non-contact point is found, machining begins, and the axes return to the original start position and normal processing begins.
  • Touch Retry: This function is intended to be used when threading small diameter holes that are located close together (close pitch spacing between different start holes), and acts in the opposite manner of the Non-Contact Search It is possible to successfully thread the wire in a close adjacent small start hole (incorrect start hole), which could damage the workpiece if machined. The Touch Retry function will automatically cut and rethread the wire when there is contact between the wire and the workpiece after the AWT process.
  • Slit Hole AWT: This function improves AWT reliability of small hole threading. The function changes the AWT water jet pressures to prevent the wire from drifting into the kerf slot or existing small cavity (especially during Recover Wire Break conditions).

Join the conversation.

Your email address will not be published.

EDMmatters 7-28-16

Faster Side Burn and Multi-Axis Vector EDM Machining Jump Speed

facebooktwittergoogle_pluslinkedinfacebooktwittergoogle_pluslinkedin

The new Hyper-i control for Makino’s sinker EDM product lines (EDAC-1, EDAF-Series, EDNC-Series) brings about new machining capabilities to help reduce machining time. One specific upgrade is in the motion control system that now enables faster Side Burn or Multi-Axis Vector machining. The new Hyper-i control system improves both the Side or Vector Jump Speed and Jump Acceleration values by tenfold. Jump Speed has been increased from 0.5m/min to 5m/min, and the Jump Acceleration has increased from 0.01G to 0.1G.

Join the conversation.

Your email address will not be published.

Tech Tips: Automatic Wire Threading Settings – Part 2

facebooktwittergoogle_pluslinkedinfacebooktwittergoogle_pluslinkedin

Are you aware of the different Automatic Wire Threading (AWT) functions that can be accessed from the OTHERS page?  Below is an overview of another commonly used function, and how it can provide greater process flexibility to your Wire EDM operations…

EDMmatters 7-21-16

R.W.B. (Recovery Wire Break)

  • This function allows the operator to change the automatic recovery actions the machine makes in the event of a wire break during machining. The different modes allow selection of the preferred methods that best support the workpiece processing while maximizing unattended machine operation. While the W.B. Mode button can always be accessed and changed from the OTHERS page, it can also be programmed directly into the NC Program. When used in a program, the R.W.B. Mode allows the best wire break recovery strategy to be automatically set for each workpiece profile, and there are three different modes that provide increased flexibility to the operator.

The R.W.B. Mode functions are as follows:

  • Switch W.B. Mode from (0, 1, 2, 3)
    • Mode 0: The machine STOPS in the event of a wire break. The machine will not move or rethread the wire, and it will wait for the operator to return to review and continue operation. This mode allows the ability for the machine or the operator to rethread the wire at the break point, and prevents the machine from positioning back to the original wire thread start hole location.
      • NC Program Code: G121L19S0
  • Mode 1: The machine will position back to the original wire thread start hole location, rethread the wire, and then rapid position back to the wire break point and continues normal automatic operation. When the number of wire breaks amounts to 5 times (default value), the machine will stop and move to the next programmed M6 wire thread point, and will continue machining to prevent loss of unattended machine operation.
    • NC Program Code: G121L19S1
  • Mode 2: The machine will position back to the original wire thread start hole location, rethread the wire, and then rapid position back to the wire break point and resume normal automatic operation. When the number of wire breaks amounts to 5 times (*default value), the machine will stop and move to the next programmed M6 wire thread point and will STOP (the machine does not continue machining). The operator must return to the machine to review and assess the machining progress. They can then continue or restart the program operation.
    • NC Program Code: G121L19S2

*Note: Parameter 100 sets the maximum number of retry times of the R.W.B. function (Default = 5 / Range from 0 to 127)

Join the conversation.

Your email address will not be published.

Tech Tips: Automatic Wire Threading Settings – Part 1

facebooktwittergoogle_pluslinkedinfacebooktwittergoogle_pluslinkedin

Are you aware of the different Automatic Wire Threading (AWT) functions that can be accessed from the OTHERS page within Makino’s Hyper-i control? Below is an overview of one of the most commonly used functions, and how it can provide greater process flexibility to your wire EDM operations.

EDMmatters Image 6-30-16

AWT Mode:

This button controls the speed and function of the AWT system. There are a total of four different modes that enable quick selection of AWT settings to provide the most reliable threading performance. While the AWT Mode button can always be accessed and changed from the OTHERS page, it can also be programmed directly into the NC program. When used in a program, the AWT Mode allows the best wire threading method to be used for every start hole.

The AWT Mode functions are as follows:

Switch AWT Mode from (0, 1, 2, 3)

  • Mode 0 – A standard AWT Mode without wire sensing for start holes that are larger than 1.0mm (0.040”) in diameter. The machine will attempt to automatically thread the wire one time and will not reverse the wire feed if the wire is hitting the top of the workpiece. The machine will STOP if AWT is not successful after one attempt.
    • NC Program Code: G121L21S0
  • Mode 1 – A standard AWT Mode with wire sensing for start holes that are larger than 1.0mm (0.040”) in diameter. The machine will automatically reverse and advance the wire feed if the wire is hitting the top of the workpiece. The machine will STOP if AWT is not successful after attempting a number of times (Threading Retry amount is controlled by parameter #7551, and the default value = 2).
    • NC Program Code: G121L21S1
  • Mode 2 – A small hole AWT Mode with wire sensing for start holes that are smaller than 1.0mm (0.040”) in diameter. This mode will automatically activate the wire annealing mechanism, which will operate every time the wire is cut to ensure wire straightness for improved small hole wire threading. The machine will automatically reverse and advance the wire feed in a fast pecking motion if the wire is hitting or touching the top of the workpiece, mimicking the methods used when manually threading the wire. The machine will STOP if AWT is not successful after attempting a number of times (Threading Retry amount is controlled by Parameter #7551, and the default value = 2).
    • NC Program Code: G121L21S2
  • Mode 3 – A high-speed AWT Mode without wire sensing for start holes that are larger than 1.5mm (0.060”) in diameter. The machine will attempt to automatically thread the wire one time at high speed, and will not reverse the wire feed if the wire is hitting the top of the workpiece. If high-speed threading is not successful, the machine will automatically attempt the rethread the wire using Mode 1. The machine will STOP if AWT is not successful after attempting a number of times (Threading Retry amount is controlled by Parameter #7551, and the default value = 2).
    • NC Program Code: G121L21S3

Join the conversation.

Your email address will not be published.