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Solutions for cost effective and high-quality machining of aerospace blisk

Aerospace blisk - HRSA

Blisks are single engine components where the hub and blades are machined from a solid piece of material.

On the cold compressor side of the turbine, Blisks are made of titanium, while the hot, combustion side requires heat resistant super alloys.

Key factors to success are:

  • 5-axes machine with good simultaneous dynamics
  • Turbo 5 axes CAM software
  • Optimized tools and process knowledge for HRSA and titanium

Tooling solutions for aerospace Blisks

ISO S Ceramic Ball Nose End Mill

The ISO S Ceramic Ball Nose End Mill is the only tool on the market which allows for high speed profiling with small diameters.

The brazed ceramic on carbide interface provides both strength and flexibility, and the ball nose geometry ensures an easier, faster profiling.

The ISO S Ceramic Ball Nose End Mill is the first choice for high productivity profiling of Heat Resistant Super Alloys (nickel-based).

Read more about this solution

ISO S Ceramic Ball Nose End Mill

CoroMill® Plura - Solid carbide ball nose end mill for profiling

The ISO S ceramic ball nose end mill is your first choice for productive profiling of nickel based super alloys, designed especially for blades and blisks. The brazed ceramic on a carbide interface provides both strength and flexibility, and the ball nose geometry ensures easy high speed profiling with small diameters.

CoroMill® Plura ceramic ball nose end mill

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Semi finishing and finishing of blade

For semi finishing of the blade, a point milling approach is recommended due to the double curved surfaces. This machining process provides for controlled stock and scallop height left for the finishing operation.

Method: Point milling, preparing the surface for the finishing operation

Process: Radial cutting depth of 0.5 – 3 mm (0.020–0.118 in) after the roughing operation


Finishing of the blade

Continue with point milling due to the double curved surfaces. The recommended solution provides a surface finish of Ra 0.4 μm (15.75 μin).

Process: Radial cutting depth of 0.2 mm (0.008 in) after the semi finish operation.

CoroMill® Plura conical end mill

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Ceramic turning

Ceramic grades CC6220 and CC6230 are designed specifically for the challenges of new HRSA materials where whisker ceramics and SiAlONs fall short, capable of higher cutting speeds, contributing to reduced cost per component. For high metal removal rates in pocketing and profiling applications, choose grade CC6160.

Ceramic grades CC6220 and CC6230

Ceramic grade CC6160


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CoroChuck™ 930

Thanks to its excellent clamping performance this chuck offers the best pull-out security on the market, for excellent stability and accessibility in milling and drilling operations. A solution that doesn’t just helps increase machining safety and precision, but also increases production efficiency through quick and easy tool set-ups and changes. For 100% pull-out prevention, a collet with mechanical locking interface is available for Weldon shanks.

Read more about CoroChuck™ 930

CoroChuck™ 930

CoroDrill® 860 with -SM geometry for highly secure drilling in heat-resistant super alloys(HRSAs)

When drilling tough materials such as HRSAs, many factors need to be taken into account. Process security, repeatability, hole tolerance and quality are critical. Equipped with a robust design, a high-quality edge and a wear-resistant top coating, the CoroDrill® 860 with -SM geometry delivers on these key considerations

Learn more about the CoroDrill® 860

CoroDrill® 860

Semi finishing of blade

For semi finishing of the blade, a point milling approach is recommended due to the double curved surfaces. This machining process provides for controlled stock and scallop height left for the finishing operation.

Method: Point milling, preparing the surface for the finishing operation

Process: Radial cutting depth of 0.5 – 3 mm (0.020–0.118 in) after the roughing operation

Tool: CoroMill® Plura conical end mill


Roughing of slots

Tool: Engineered solid carbide plunge cutter with Gannet® geometry

Method: Rough opening between blades – plunge milling

Advantages compared to conventional full slot milling

  • Higher productivity
  • Process security
  • Less inventory


 
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