MAX CAM Software

Understanding the Elements: The Coordination of Materials, Coatings and Geometry

Manufacturer Competes with MAG3 MMC Investment

Most Powerful Integral Drive Spindle in the World Available

A66E-5XD Five-Axis Machine Ideal for Turbine Parts

Makino's A99E-CD Offers Aerospace Productivity and Flexibility

	For the aerospace industry, one of the more exciting innovations to spring out of the machine tool technology revolution has been the evolution of high-speed machining. Not only are spindles and guideways capable of going faster accurately, but also better controls and CAM software ensure the machining program can keep up with the machine. Alan Levine is Director, Computer-Aided Manufacturing at Concepts NREC. The company produces its own line of CAD/CAM/CAE software and also designs and develops turbomachinery components for several companies. He reinforces the impact high-speed machining has had on the industry. "I have seen a customer reduce machining time up to 55 percent over the past four years using high-speed milling," says Levine. He adds the company also had to outsource less work to finish jobs on time—a significant bottom-line enhancer. The impact of these machines does not stop at producing quality parts quickly. There is also great potential in machining smaller components from block material instead of a higher-priced casting, or in taking previously separate components and combining them, as with blisks (bladed disks or IBRs, Integral Bladed Rotors). According to Levine, it was not so long ago where blisks or IBRs would never enter the high-speed machining equation for the aerospace industry. "Blisks could not be made large enough or accurately enough, and were too expensive. They also greatly reduce the number of parts in an engine, simplifying assemblies and balance procedures." Concepts NREC's MAX-series of CAM software tools—developed for producing toolpaths for turbomachinery components—generate toolpaths that take into account the hard materials used to make blisks (like titanium), the thin walls of the blades, machining the tight quarters between blades, and the ultra-high tolerances and quality requirements. CAM packages like the MAX-series complement the advanced high-speed machining centers like the Makino V55-5X with cutting techniques like Flush Fine, which combines a shallow depth of cut to keep heat away from the part with high spindle speeds and cutting speeds. Flush Fine works well on the blades of the blisk since the low heat means the thin walls are much less likely to distort. Super Geometric Intelligence (SGI) software is another innovation in the V55-5X that maximizes the original CAM program. The servo control software looks ahead of where the program is and makes corrections. It also lets the machine know what is ahead so feed rates for toolpath changes can be optimized to reduce the risk of marring the blisk. The Makino V55-5X also has a five-axis table with a dual tilt mechanism, which brings the part to the spindle from more angles, so the spindle does not move as much, keeping chatter and undesirable conditions at bay. Copyright © 2001 - 2008 by Makino, Inc. All rights reserved.