Blisk machining on Breton Xceeder 900 RT high performances machining centres

Xceeder 900 RT

Blisk is a titanium or inconel aero engine part used in the cold section. In the past blisks was made with many single blades locked in a rotor shaft, but today the new trend is to have the blisk made in only one part.   

For this purpose customers need machines tools more sophisticated and efficient to have the maximum reduction of production time. In this case  the blisk milling process start from a titanium  blank with  diameter of 620 mm, thickness of 130 mm, 19 blades of 180mm height. The single blade thickness vary from 2 mm at the end  to 4 mm at the centre. 

Breton goal was to define tooling and technology to work the blisk in only one set-up cutting down the actual total working time.

The blisk is machined with Breton Xceeder 900 RT, 5 axes high speed vertical milling center with direct drive rotary tilting table with X,Y,Z stroke of 900x900x600 mm rapid axes up to 60m/min and electrospindle of 40 kW continuous power, 137Nm torque and 18000 rpm. 

The toling is studied to accept different kind of blisks and with only one locking procedure the operator can clamp the piece with the right preload. 

Roughing phase  is obtained with two different strategies: at the first the machine open the cavities with  three axes step plonging strategy and than it take away the rest material with three axes step contouring. 

Figure 01: a 19-blade blisk for turbojet bypass aircraft engine

Figure 02: raw part, forged in Titanium (Ti Al6 V4)

Figure 03: workpiece placement on the machine

Figure 04: workpiece rough-cutting in axial penetration

Figure 05: 1st level roughing-out in axial penetration

Figure 06: 1st level roughing-out restart in contouring

Figure 07: 2nd level roughing-out in axial penetration

Figure 08: 3rd level roughing-out in axial penetration

Figure 09 : Bottom semi-finishing

Figure 10: Reduction of the blade bottom union

Figure 11: check with penetrating liquids

Figure 12: Ball set-up PHASE before starting the mechanical probe calibration. 

Semi-finishing and finishing blade and bottom phases are realized with continuous five axes strategy. 

Breton for these applications has developed also a special software to measure in process blade’s dimensional and geometrical parameters and it is capable with the measuring result to adjust the final working cycle  to obtain the blade in the defined tolerances.  

The final result is that Breton with its machine and technology has saved the 23.8 % of the total working time.

Figure 13: view of the bottom, blade – bottom union radius machining

For more INFO click here or write to mail@breton.it

By-by

Sergio Prior

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5 axis machining centers, aerospace machining, blisk, breton machining centre, vertical machining centre, xceeder

Breton MATRIX - High-speed machining centres with five interpolated axes

Matrix 800-1000-1300

Matrix is a new range of machining centres with a gantry structure and moving cross beam designed and developed by Breton to satisfy the new and demanding manufacturing  requirements for  high-speed machining of complex and large size workpieces across various applications for die manufacturing, model making and styling.

Rigidity and high dynamics are distinctive features of this range making it ideal for machining a multitude of components and products at high speeds with maximum milling performance.
Matrix thanks to the speed of the linear axes which reaches up to 40 m/min, to the Direct Drive head with a rotational speed of up to 100 rpm and to continuous rotation of axis C,  this machining centre is the perfect solution for specific production requirements  as profiling complex workpieces with 5 continuous axes ensuring and guaranteeing maximum machining precision and performance.

The direct drive twist head, which can be positioned at any angle thanks to the powerful hydraulic operated brakes, allows for mounting 40kW spindles with rotation speeds of up to 28000 rpm providing this work centre with improved milling efficiency and performance.

The various available configurations of the Matrix range (travel X from 2500mm on Matrix 800 to 3900mm on Matrix 1300, Y from 2000 mm to 8000mm, Z from 1000mm to 1600mm) make these work centres the ideal solution for machining medium to large workpieces across a number of materials as steel, aluminium, resin and composite materials.

The closed structure and drive assemblies mounted on the top part of the machine, ensure maximum operator safety and maximum machining precision, performance and reliability.

Machining precision and quality are further enhanced  by the thermal symmetry of the machine  structure, and by the thermal stabilising system which stabilises and maintains the temperature of the balls nuts, bearings on axis Z and  axis drives  at the same temperature as that of  the machine structure.

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aerospace machining, automotive machining centre, breton machining centre, die, high-speed machining center, matrix, mould, vertical machining centre

Our customer FUTURAMIC

Futuramic is a ground-breaking American company which produces components for the aerospace, aviation, automotive and shipbuilding industries.

Futuramic was awarded the ISO 9001 Quality Certification in 1998, and is the qualified and approved supplier of the following customers:

Honda HMA, Honda MAP, Vought / Aerostructures Company, Karmax Heavy Stamping, BAE Systems, KTH Parts Industries, Bell Helicopter Textron, Lockheed Martin Tactical Aircraft Systems, Lockheed Martin Manned Space Systems, The Boeing Company, BMW, Magna Heavy Stamping, Bombardier Aerospace, Massiv Die-Form, Cessna Aircraft Company, Ogihara America, Daimler / Chrysler, Raytheon, Drive Automotive, Subaru-Isuzu Automotive, Embraer, Thyssen-Budd Company, Ford Motor Company, Tower Automotive, General Motors, Vought Ind., Honda ELP (East Liberty, Ohio), Yachiyo of Ontario Mfg., Inc., and many others.
Futuramic owns a large fleet of high-speed machining centers including no less than six Breton's machines:
- n.1 Flymill 2000
- n.3 Matrix 800
- n.1 Matrix 1300
- n.1 Xceeder RT

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5 axis machining centers, aerospace machining, breton cnc 5 axis, CNC turning and milling center, flymill, high speed cnc, matrix, steel, superalloys, Vertical turning milling center, xceeder

Breton ULTRIX 1000 RT HD - Five axes, still and always

Ultrix 1000 RT HD, highly automated high-speed machining centre with 5 axes, engineered for milling, turning and grinding operations on up-to-1200mm diameter pieces. This machining centre is equipped with a powerful 75 kW, 300 Nm, 14.000 rpm spindle and with software for the cut of Klingelnberg and Gleason bevel gears. This is Breton’s answer to the constant demand for quality and precision in high automation production systems for the machining of mid-sized and small parts. 

Ultrix vertical machining centre is specifically conceived for machining steel, aluminium, superalloys and composite materials.

It features a gantry structure with mobile cross beam. The 5-axes movement is generated by the three linear axes combined with a rotary tilting table.

There are several models of Ultrix CNC milling and turning centres to choose from: the 800 (with 4 axes), the 800 RT and the Ultrix 1000, 1000 RT and 1000 RT HD.

The table rotation is around a C axis that can reach 1.000 rpm when turning. The A tilting axis can reach 100 rpm. The linear axes feature a speed of up to 60 m/minute. Ultrix are multipurpose machining centres performing consistently the horizontal and vertical turning, milling, drilling and grinding, with just one positioning of the piece.

 

The turning boring bar placed on a side of the vertical ram enables to turn externally pieces which are higher than the Z travel thanks to the additional 150 mm vertical stroke of the boring bar. In addition, this allows our milling and turning centres to use shorter tools, thus jolts are reduced and the utilization of vibration-damping bars is limited only to very deep turning operations on full-hard materials. 

Furthermore, Ultrix high-speed milling and turning centres can be fitted with a turning/milling spindle which, enabling to swivel the turning tool in various positions, allows to swiftly change from the vertical to the horizontal turning of the same piece, so as to optimize both the machining and the tools and, when working diagonally, to turn even pieces up to 1.000mm in diameter.  

All Ultrix models can be equipped with a tool-store holding 30, 60 or 150 tools, automatic pallet-changing facilities and an array of options to fully tailor the machine to the customer's various needs.

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aerospace machining, breton cnc 5 axis, CNC turning and milling center, Gleason bevel gears, high-speed machining center, Klingelnberg, mi, Ultrix breton, vertical machining centre