Turbine blade manufacturing is a varied field from aerospace engine compressor blisks and rocket turbopumps, rotors and stators of large steam and gas turbines, to the world of blades and vanes. Many of these precision, high temp alloy part designs require 5-axis machining and also advanced cutting tool designs to be successfully manufactured. Emuge offers a wide range of solid carbide end mills that are used extensively in this industry. We also have partnered with leading CAM software providers and can assist customers with best practices programming recommendations.
CIRCLE SEGMENT CUTTERS
The circle segment end mild constitute a new tool class which enable machining with a larger tool path distance during pre-finishing and finishing operations. These tools are primarily used in plastic mold-making as well as in the production of tire molds, turbine blades, impeller blades, or blisks. The technical advantage of these end mills are the large radii in the cutting area of the respective tool which offer entirely new possibilities in machining.
The large radius simulates a ball-nose end mill with a cutting diameter of 2 to 3,000 mm and even larger on request. The large radii cutting tools dramatically increase the step-over width for each cutter pass and therefore milling times.
The CAM software system that has to support and compute the geometry of the circle segment end mill, plays an important role here. Emuge's technical support personel can assit in selecting the proper tool geometries as well as developing the optimum milling tool paths. As a consequence, machining times can be reduced significantly and at the same time, the surface quality of the components is increased.
TAPER BALL & TORUS NOSE CUTTERS
Tapered Ball Nose end mills along with Torus Style end designs provide maximum performance in turbine blade and impeller milling applications. Emuge offers a full line of premium quality carbide end mills with unique tapered and flute designs in a variety of lengths and sizes. Application and programming assistance is also available on request.
PAGODE FORM END MILLS FOR TURBINE ROOTS
Milling cutters with pine-tree design are used for finishing blade root grooves and blade roots of turbines. EMUGE-FRANKEN has upgraded this style cutter geometry and call the new style Pagode. The Pagode form end-mill has a different design of the chip flutes, in which the chip depth is individually adapted to the machining allowance of the workpiece. This contour-accurate adaptation of the chip flutes allows for a doubling of the number of teeth and thus an increase in feed rate.
In order to supply the cutting edges with sufficient coolant despite the reduction of chip space, the Pagode form end mill was designed with significantly more coolant exits. Due to the larger helix angles, two cutting edges always work simultaneously on the workpiece. This results in a smoother running tool and an excellent surface quality. The tangential relief grind of the cutting edges contributes to less wear and a longer tool life. The Pagode form end mill is produced individually according to customer specification and it can be used in high-alloyed and highly heat-resistant steels. It is configurable in diameters from 40 to 200 mm and cutting lengths from 50 to 200 mm. Contact Emuge for more information.