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PROJECT TEAM · PRACTICAL EXAMPLE

Turbine Blade

High-precision machining of a turbine blade in heat-resistant superalloy using advanced multi-axis strategies.

Overview

High-precision machining of a turbine blade in heat-resistant superalloy using advanced multi-axis strategies.

Objective

Achieve efficient and stable machining of complex geometry in Inconel 718 while maintaining high surface quality and tool performance.
Turbine Blade

Key Facts

• Material: Inconel 718 (solid)

• Application: Aerospace turbine component

• Machine: 5-axis machining centre

• Complex freeform geometry

MACHINING SETUP AND STRATEGY

5-Axis Aerospace Machining Environment

Machining Environment

• 5-axis machining centre (MAZAK Variaxis i-700)

• High-speed spindle capability

• Advanced CAM programming

Process Strategy

• Combination of roughing, semi-finishing and finishing

• Optimised toolpaths for complex geometry

• Controlled cutting conditions for HRSA materials

A Three-Stage Cutting Strategy

1. Roughing

JRF Milling Cutter / Ceramatic Brazed

• High-efficiency material removal

• Ceramic and high-performance tools

• Stable cutting at high speed

2. Semi-Finishing

AddForce Barrel

• Barrel tool strategy for surface coverage

• Reduced machining passes

• Increased productivity

3. Finishing

TungMeister

• High-precision surface finishing

• Tight tolerance control

• Optimised surface quality

PROCESS PERFORMANCE

CAM Estimate vs. Actual Cutting Time

Stage Tool Line CAM Time Actual Time
Roughing JRF (NTK) 2 min 57 sec 2 min 58 sec
Blade Roughing Ceramatic Brazed (NTK) 2 min 54 sec 4 min 27 sec
Blade Semi-Finish AddForceBarrel (Tungaloy) 6 min 30 sec 6 min 57 sec
Platform, Rough TungMeister (Tungaloy) 15 min 15 sec 17 min 26 sec
Platform, Semi TungMeister (Tungaloy) 5 min 18 sec 5 min 21 sec
Blade, Finish TungMeister (Tungaloy) 21 min 00 sec 21 min 31 sec
Platform, Finish TungMeister (Tungaloy) 16 min 09 sec 17 min 39 sec
Total 70 min 03 sec 76 min 19 sec

• Stable machining of Inconel 718

• Optimised multi-axis strategy

• Improved productivity and efficiency

• Consistent surface quality

Result

Stable Machining of Inconel 718 With Consistent Surface Quality

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