TURBINES - Turbine Milling

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CNC TURBINE MILLING

Both blades and rotors are very complex shapes characterized by variable geometry of the shape of the parts, which results from the need to change the pressure at the inlet and outlet of the turbine. This is done by changing the flow rate of the medium between the surfaces of both elements. While correct modeling of rotors using available CAD software, e.g. SOLIDWORKS, is not currently a major problem, the implementation of a 3D model and the reflection of the designer’s vision in the form of a finished detail is one of the most advanced processes of manufacturing machine parts.

The environmental conditions in which the rotors operate, i.e. high pressure, high rotational speeds, high temperature, require the use of wear-resistant materials such as aluminum, titanium, chromium and nickel alloys. The above-mentioned materials belong to the group difficult to machine, which additionally increases the technological difficulties in milling turbines. Each element must be made with high precision to meet rigorous quality standards including the condition of the external coating and the tolerance of geometric dimensions.

Turbiny w technologii CNC

A flow engine that uses the energy of a flowing medium to generate mechanical energy is a very complex mechanical device. Currently, such structures are used in the energy industry, as well as in the transport industry. The design of turbojet engines and power turbines is similar, and in the following part, aspects of the implementation of key elements will be discussed. The main structural element, apart from the external housing, is the shaft, on which the drum or ring forming the blade palisade is mounted. The above-mentioned elements form a set called the rotor.

The countless number of blades that make up the blade palisade are responsible for contact with the flowing medium. As a result, a torque is generated on the rotor shaft that sets the entire turbine in motion. Turbine structures are also distinguished, in which the rotor is a monolithic element, containing fixed blades connected to the hub without the possibility of dismantling individual parts. In such a solution, the rotor is made of a single block of material. This solution is used, for example, in the automotive industry in turbochargers of supercharged combustion engines.

What technologies are used to make rotors?

Currently, there are two technologies for making fixed (monolithic) rotors. The first is making the rotor as a casting in a previously prepared form. In the case of serial production of turbines, this is a cost-effective method, but rotors made in this way have disadvantages. The first is a large difference in the homogeneity of the structure of the cast rotor material. This results in reduced strength. In the case of high rotational speed, reduced strength can cause the rotor to burst.

The second disadvantage that eliminates the casting method in more loaded structures is uneven rotor balancing. This generates an additional verification process and also entails the need to improve the balance and introduce geometric changes in already made elements.

CNC Turbine Design

In structures requiring high strength and long-term reliability rotors made from a block of material by milling turbines, rotors using multi-axis numerically controlled machines are used.

Using the capabilities of advanced machining centers, the kinematics of which allow the tool to be positioned relative to the processed material in any position and requires the preparation of machining technology in CAM-class support systems. CAMWORKS software is a system offering very advanced functions.

High technological requirements justify the use of advanced machining centers in the process of making turbine elements, and knowledge and practice in the field of rotor machining is the key to their correct execution.

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17 741 53 50

SOLIDEXPERT INNOVATION Spółka z ograniczoną odpowiedzialnością
ul. Gabrieli Zapolskiej 44, 30-126 Kraków
fax. 17 741 53 50, biuro@innovation-se.com
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