Using an ANCA 'RGX' tool and cutter grinder. Wilson & Wylie has manufactured a complete series of fir tree' profile cutters These include a one piece BT50 taper shank cutter produced with eccentric relief in ASP 30 especially developed for machining the matching male and female forms into exotic alloys used in turbine blade applications. Given the critical performance demanded from blades, tolerances on the fir tree forms are now typically held to +-5#mu#.Cutting tools used in fir tree applications are up to 150mm diameter with a cutting length of 100mm. With tools of this size and weight a conventional cutter/spindle tooling combination cannot deliver the accuracy required. To overcome this a one piece cutter which incorporates both fir tree root cutting form and a BT50 taper ensuring concentricity between cutter and spindle has been developed. A tool of this type could take up to 80 hours to produce using conventional cutter grinding machines.
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