PRODUCT REVIEWS
Waterjet cutting for jet engine turbines
When fabricating jet engine turbines , wire EDM is often used since the technology provides narrow cuts for precise and complex shapes . However , wire EDM is also a timeconsuming manufacturing process ( set-up time and processing ). It is also a thermal manufacturing process which influences the properties of the material . However , new and innovative waterjet cutting technology is now being proposed for this aerospace application .
“ Fabricating turbines for jet engines is a time-consuming process that requires precision . Since wire EDM is recognized as a quite slow machining technology , an international jet-engine supplier explored the possibility of reducing the manufacturing time of fixed turbine parts by replacing wire EDM with other processing technologies . The challenge was to find a technology that could meet the tough requirements ,” explained Water Jet Sweden ( WJS ).
“ Thermal cutting technologes , such as laser and fibre laser , were tested but there was too much heat impact on the material , so laser cutting had to be rejected . The next step was to investigate waterjet technology as an option . The drop-shaped contours of the jet turbine required five-axis machining and , at the same time , a very narrow cut to handle small
FiveX Ultra with micro cutting head for advanced waterjet cutting .
contours , sharp corners and small tolerances , with a fine cutting surface ,” it added .
Traditional waterjet cutting was difficult to apply , but the challenge was met by the new FiveX Ultra waterjet cutting system from Water Jet Sweden . FiveX Ultra is a full 3D cutting machine ( 0-120˚ cutting ) designed to manage precision cutting assignments . As the FiveX Ultra can be equipped with a FAWJ Micro Cutting Tool , it also provides extremely fine cuts for precise and complex shapes .
Following a customer visit to the Water Jet Sweden Demo Centre in Ronneby ( Sweden ), the development of a new manufacturing routine for jet engine turbines started .
Waterjet cutting is a cold cutting process , with no heat-affected zones , and the cutting surface is “ satin smooth ” according to
WJS . With the narrow cutting beam of the micro cutting tool , it cuts sufficiently sharp corners but adjustments needed to be made to the slightly cone-shaped cutting beam ( a characteristic of waterjet cutting ). The TVL ( tapered angle control , variable speed and delay compensation ) function was fine-tuned to eventually provide an approved cutting profile .
“ The fact that it was not possible to make direct measurements of the parts was a challenge in the work process . Instead , interpreters are used to check the contour accuracy . In small steps , the process was gradually optimised to finally obtain the correct and precise profile . We have now developed a process to optimise cutting parameters for turbine production , using a unique combination of our new 3D waterjet cutting machine and our FAWJ micro cutting tool ,” explained Tony Ryd , Co-Founder and CTO , Water Jet Sweden .
Time savings were made over several stages of the manufacturing process . Cutting times were improved , set-up time could be reduced to a minimum ( with fixtures instead of time-consuming wiring ) and a new auto calibration tool significantly reduced the time from loading to production . n
www
. waterjetsweden . com
Digitalisation in sheet-metal processing
TRUMPF spin-off Optimate is continuously developing its solution for AI-supported feasibility analysis and part optimisation . Its cloud-based software , which can be used both as an App and CAD plug-in , now has integrated cost-calculation functionality .
Optimate CEO , Job shoppers and OEMs who Jonas Steiling . produce and design sheetmetal-based products now only need one click to calculate the costs of their parts . “ With the Optimate App , product designers and sheet-metal processing companies can identify defective parts in advance and adjust them if necessary , even before they enter production . In addition to analysing individual parts , assemblies with up to 25 individual parts can also be checked for feasibility and optimisation potential ,” outlined Optimate .
Up to now , the App has given a percentage indication of the potential savings of the optimised design compared to the existing variant . This was a good indicator to determine changed production costs . For individual manufacturing costs , the indicator held potential for optimisation of the product . “ With the introduction of integrated cost calculation , this is now even easier and more precise ,” emphasised Jonas Steiling , CEO , Optimate . ‘ Our users receive the specific price for their sheet-metal parts at the touch of a button .”
The calculated sum is based on the contributing cost factors for material , scrap and the manufacturing process i . e . the complete sheet-metal process from laser cutting to bending and welding . In addition to the material costs , the costs for scrap , set-up and production times as well as machine hourly rates are also included in the sum . Based on the classification , companies in sheet-metal processing can then break down the costs for the detailed product processing steps . Once the cost drivers have been identified , the optimisation potential can be shown .
Users can also create their own profile in the Optimate App . The information stored with respect to machinery and tools is then also used for optimisation and individual cost calculation . These cost forecasts benefit not just the designers themselves , who can identify possible cost drivers already in the development process , but also other areas such as purchasing , controlling and cost calculation for sales .
“ This makes it easy for buyers and jobshoppers to calculate the costs of sheetmetal parts online . Sales department can quickly create suitable offers for even the smallest batches or individual parts in a timely manner and without much effort ,” summarised Optimate .
“ Benefits range from accelerated development processes and long-term planning as well as reliability in production to solid price and quotation calculation – and all in a matter of seconds ,” concluded Optimate CEO , Jonas Steiling . n
www . optimate . de
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