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Wire EDM can replace broaching for fir tree slot production

Veselovac, Process monitoring and control of machining operations, International Journal of Automation Technology, Vol. Broaching can produce high precision and good surface finish at a high metal removal rate. Finally, optimum tooth geometry and rise per tooth have been recommended for tool performance, broached surface quality and efficient chip formation. With the soaring demand for new aircraft by the year , and with every passenger jet requiring more than fir tree slots, it was obvious to Welling that a more efficient and secure fir tree slot manufacturing method was needed. This paper deals with developments of Wire-EDM technologies for fir tree slot production. GF Machining Solutions keeps aerospace customers flying high.

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This paper deals with developments of Wire-EDM technologies for fir tree slot production. The aim of these developments is to substitute certain conventional processes within turbine manufacturing that have been identified as non-optimal like the critical broaching process.

Thereby the negative characteristics like inflexible manufacturing processes, high machine tool investment costs and huge energy consumption can be abolished. The objective targets of the conducted research are to meet all safety requirements of the critical components and get an economic manufacturing process.

In the first step a special brass wire technology for cutting Ni-based super alloys was developed. Main focus was to meet the requirements of fir tree production concerning aspects of surface integrity and geometry. To measure these aspects on the one hand non-destructive analyses have been performed to guarantee surface roughness and accuracy. On the other hand destructive analyses in terms of cross section polishing for showing thermal influenced rim zones have been prepared.

A capable Wire-EDM process is presented. Jayal, Surface integrity in material removal processes: Veselovac, Process monitoring and control of machining operations, International Journal of Automation Technology, Vol.

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