CAD/CAM solutions for efficient machining of turbo machinerycomponents by Sturz milling method

摘要

Rapid developments in the fields of engineering and theirapplications in manufacturing processes have brought real changes inproduct designs, evolving more efficient and complex designs.Application of ball end machining for generating complex sculpturedsurfaces tends to be nonproductive especially in places where largesculptured surfaces and/or large volume of production are involved.Kaplan blades are one of the vital components in hydro turbines whichhave large sculptured surfaces and involve bulk metal removal whilemachining from forged blanks. Conventional ball end machining methodsare not adequate to achieve the required productivity and quality whilemanufacturing these components. With the advent of multi-axes CNCmachines and powerful CAD/CAM solutions-“Sturz milling”, aninnovative method of sculptured surface machining has become not onlyfeasible but also cost-effective for the production of these components.This paper discusses the Sturz milling method, control parameters, it'sperformance in comparison with conventional ball end milling and alsothe customisation of the CAD/CAM CNC programming solutions to evolveefficient machining patterns