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Classic five-axis machining-impeller parts solution evaluation

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Evaluation of Five-Axis Milling and Turning Composite Machining for Impeller Parts by SPI

A set of aluminum alloy impeller parts has relatively large dimensions and many rotational features, so we are considering purchasing the Jingdiao JDMRMT600 milling and turning composite machining center. Customer requirements: first evaluate the processing plan, and provide the processing verification time and verification cycle.

Basic Part Information

Material: 6061 Aluminum Alloy
Dimensions: Ø589.37330.2 mm, Ø622.3320.04 mm
Requirements: Surface roughness Ra < 0.32 μm; dimensional and geometric tolerances to be processed according to the drawings.

Equipment Plan

The Jingdiao five-axis milling and turning composite JDMRMT600 (P18SCHT) equipment will be used for machining. This machine can perform five-axis simultaneous milling for impeller blades, turning for rotational features, as well as drilling, reaming, and tapping for hole features in composite machining. The JDMRMT600 (P18SCHT) is a five-axis milling and turning composite machining center, mainly suitable for high-efficiency five-axis milling and turning composite processing of complex parts with rotational features, such as casings, discs, and sleeves.

Impeller Part Clamping

For the roughing process, pre-machine threaded holes on both sides of the blank for roughing clamping. Use screw-locking for clamping and fixation, providing greater stability during high-efficiency roughing with large cutting volumes. For five-axis simultaneous finish machining of the blades, clamping and fixation can be done using pressure plates.

Impeller parts horizontal lathe processing

The blank is first turned on a horizontal lathe. According to the maximum outer contour of the part’s rotational characteristics, it is turned into a ring state, leaving a 1mm allowance on one side.

Impeller blade roughening

The turned blank is clamped on the five-axis equipment to rough the blade features.
The roughing is done with an aluminum alloy side milling tool and a multi-axis side milling impeller roughing strategy for efficient roughing, with a single-side allowance of 1mm.

Impeller blade finishing

Use a tapered ball-end tool to finish the impeller and flow channel features.

The precision machining of turbine blade components is a complex and highly demanding process, especially in industries such as aerospace, power generation, automotive, and turbine machinery, where the precision and surface quality of the blades directly affect performance and durability. This process typically involves several key stages:

1. Design and Material Selection

Material Selection: Turbine blades are typically made from high-strength, high-temperature, and corrosion-resistant alloys such as titanium, stainless steel, or aluminum alloys. Choosing the right material is crucial to improving the blade’s performance.
Design Precision: The design of turbine blades requires extremely high precision. Even small deviations in the design, especially in aerodynamic performance and heat treatment, can lead to efficiency loss.

2. Rough Machining Stage

Milling: Initially, rough machining is performed using CNC milling machines or 5-axis CNC machines to remove excess material. The primary goal at this stage is to form the basic shape and outline of the blades.
Tool Selection: The choice of cutting tools depends on the material’s hardness and complexity. Typically, coated tools or carbide tools are used to improve cutting efficiency and extend tool life.

3. Precision Machining Stage

Surface Treatment: During the precision machining process, finer cutting tools are used to ensure surface quality, while the aerodynamic profile is refined. This stage usually involves very small cutting amounts to achieve high precision and smooth surface finishes.
5-Axis CNC Machining: To ensure the complex shape and precision of the blades, 5-axis CNC machining is commonly used. The 5-axis machine allows multiple adjustments in different directions simultaneously, making the machining process more flexible and suitable for intricate blade designs.
Tool Path Optimization: During precision machining, the tool path needs to be carefully calculated to avoid uneven or rough surfaces.

4. Heat Treatment

Many blades require heat treatment (such as annealing or quenching) after machining to improve their strength and hardness. Heat treatment alters the microstructure of the material, further enhancing the blade’s properties.

5. Inspection and Quality Control

Coordinate Measurement: After precision machining, the blades are thoroughly inspected using high-precision coordinate measuring machines (such as Hexagon CMMs) to ensure dimensional and shape accuracy.
Surface Roughness Measurement: The surface roughness of the blades must be strictly controlled to ensure efficiency during fluid flow.
Thermal Deformation Testing: For applications like turbine blades, thermal deformation testing is necessary to ensure performance under high-temperature conditions.

6. Post-Processing

Polishing and Coating: After precision machining, the blades are often polished to remove minor surface defects and improve surface smoothness. In addition, some blades undergo coating treatments to enhance their wear resistance and corrosion resistance.

Through these precision machining processes, turbine blades can achieve the high accuracy and quality required for various advanced applications. Do you have any specific turbine blade machining projects you would like to discuss?

Team SPI

This article was written by various SPI contributors. SPI is a leading resource on manufacturing with CNC machining, sheet metal fabrication, 3D printing, injection molding, urethane casting, and more.

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