Barrel Cutter type and precision automatic Tool-Holder collision avoidance PowerMill’s dedicated Blade, Blisk and Impeller (BBI) tool axis control and smoothing algorithms coupled with automatic collision avoidance and verification made the programming experience faster and easier with few iterations and minimal post-calculation editing required. Typically these cutter types can be difficult to program and control due to a combination of the large radius cutter form and desire to minimize the tool-axis motion whilst avoiding holder collisions with the part. The Barrel form enables a greater stepover to be achieved and cycle times to be reduced. Barrel type roughing and finishing cutters were then used to finish the part. ![]() This approach was modified to use a slotting operation to cut out each aerofoil profile removing the maximum amount of material in as little time as possible to produce a near-net shape. The toolpath combination and approach used was completely different from the conventional approach which would traditionally comprise of many shallow but fast cutting passes and be limited to Ball cutter types. These unpredictable forces result in either inconsistent material conditions or machining marks being left on the aerofoil surface. This results in a constant push/pull effect on the material and aerofoil being machined. In particular, the motion of and load on the cutter is constantly changing. Aerofoils are typically tall and thin and so they move and vibrate during the machining cycle which causes problems. To achieve this all aspects of the machining process were considered not only the cutting strategy but also the machine tool, fixturing, cutters and cutter holders too.īlisk aerofoil toolpaths usually consist of many shallow roughing, semi-finishing and finishing passes utilizing ball nosed cutters. GCD’s intent was to make a huge reduction in machining cycle time. Pre-Turned forging blank, this is the input condition to the 35 hour machining cycle time
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