The AMRC Rotatives team continue to lead the way in innovative, world leading research that is positively affecting the production of Shafts and Discs for the Aerospace industry.
The rotating parts of an aero engine play a critical role in the performance and efficiency. They are traditionally complex components made out of the latest temperature resistant materials. These materials include the latest ‘Super Nickel Alloys’ that are extremely hard and difficult to machine. The AMRC Rotatives team have drawn upon the resources at the AMRC and revolutionised the production of Discs and Shafts by incorporating the AMRC ‘critical path’ approach to manufacture. This ‘High Performance Manufacturing’ technique comprises numerous elements including analysis of cutting tools, work holding, coolant type and application, NC programming, cutting strategy and parameters, on machine inspection and assessment of machine tool rigidity. This has enabled the team to make significant process improvements by reducing the number of operations and cycle times while improving conformance.
The team are active in ongoing research in the latest cutting technologies, the next generation of shaft and disc materials, cutting strategies including NC programming, understanding the effects of residual stresses and continued application of the technology into our partners’ facilities with on-site implementation by AMRC personnel.
Key areas of current Research include:
- The use of Cubic Boron Nitride (CBN) inserts for finishing applications
- Intermittent turning of hard materials while maintaining surface quality
- Machining trials of the next generation of shaft materials
- On machine inspection including scanning
- Laser assisted turning to assist swarf control
Key Machining Resources include:
- WFL M100 MillTurn
- Hermle C50 5-axis MillTurn
- Mori-Seiki NT6600 TurnMill Centre
- Mori-Seiki NT5400 multi-axis MillTurn
- Mori-Seiki NMV8000 5-axis Vertical Machining Centre
- Mori-Seiki NVL1350 Vertical Lathe
For more information, please contact:
Phil Kirkland, technical fellow
Ian Ness, manufacturing engineer and NC programmer