XCEEDER 1200 RT - INCONEL BLISK HIGH SPEED MACHINING

[Choice777]

wouldn't it be easyer and faster to make a wax model and use the lost wax technique ?

[evbunke2]

@Choice777 Good luck! Inconel is some pretty specialized stuff, for some very specific applications. You can't just melt it and pour it into a mold.

[mentalabsence]

Nice music



[myth446]

what happens at 4:05?

[TheBodvarg]

have you americans stopped using old fasioned letter combinations for feedrate and stuff like that ????

speed=n

feedrate=Vf

feed=Fz

number of teeth=Z

cutting speed=Vc

[DanFrederiksen]

it looks very nice but that's way too long for a single piece. we have to make better production techniques

[skaterfugater]

@DanFrederiksen no we need better materials. both for the tool and especially the workpiece. If fanblades and attachment would withstand higher forces we wouldn't need a blisk in the first place. Not even for a Eurofighter (if I'm not mistaken, that's what the fan there is for.)

[apage251]

Regardless of being machined from a single piece of alloy, that piece must still be balanced using special balancing equipment.

[mattprs3]

being u have like a couple hundred hours in one part does that mean that piece cost like 100k plus?

[mattprs3]

What keeps the blade from chatter which would also take it out of balance as well.The fact of such high sf,or light cuts and posotive rake angle?

[schaapzak]

Looks like LM2500 stg 0 Blisk????

[DETHMETALTRASH]

GUAO LO UNICO QUE PUEDO DECIR ES QUE ARRECHO LA PROGRAMACION DONDE ESTAN ESTAS MAQUINAS CUANTO CUESTAN Y SI ALGUNO LA TIENE EN VENEZUELA...UFF MI SEGUNDO AMOR EN LA VIDA LAS MAQUINAS...

[WolfenGeist]

awwww this is pure awesomness!!

[bagalut]

It has to be one part because of ridgidity reasons. Stiffness, exact geometry, one material only etc.

[bagalut]

What is the waxy substance?? Häääh.

It is just coolant sticking to the blade walls. Like rain on a wiped window.

Oily rain for sure. No wax.

Casting needs perfect homogenity inside the material. Welding is unuseful as well.

[MrPrem76]

thanx ..i am doing my projcet on variable axis blisk machining

[hazzard77]

@SPUNKKK No. (Oviously) ^_^

[StickerMedia]

@SPUNKKK Haha, you're not into these things i guess? xD

They'd be welding if that'd work xD

[lexichronicle2]

@SPUNKKK Some of these rotors (as you'd find in turbines, turbo pumps and centrifuges) can have half a million to a million G on them when they're running at full speed, which means a single gram of imbalance will then become one ton's worth of load, whirling around a hundred thousand times per minute. The thing will pretty much 'explode' when it fails, as it will contain about the same amount of energy as a stick of dynamite at that speed. It all needs to be one, homogeneous piece.

[dargonz350]

you would cry if the apprentice dropped it.

The wax is to stop chatter (vibration) on the finishing passes

[acuchemkid2007]

the actual time to machine it is 94 hours and 48 minutes. It is almost 4 full days of machining. The waxy substance between the blades is most likely paraffin wax.

[MrPrem76]

yes it is awesome can any one tell me the name that wax type of fixture (white color) between the blades at the time of finish machining.

[acuchemkid2007]

@MrPrem76 It is most likely paraffin wax.

[acuchemkid2007]

@MrPrem76 another thing I thought it could be is lard.

[taystew]

that is a serious ceiling fan

[YoungJim409]

Nice demo part. I can't see this being for production when you could do a wax and investment-cast it in perhaps two or three days rather than two weeks on what I assume is a very expensive machine.

[kylep2]

"Tool Lenght"

I hope their machining is more accurate than their typing.

[lexichronicle]

Some are investment cast on a blade by blade basis as well, depends who's making the turbine, but they still use similarly super controlled heat treatment schedules. Model turbines for RC planes have their entire disc cast in one go. No need for the insane levels of heat treatment there, with it effectively being an expensive toy as opposed to something that'll kill hundreds of people when it goes wrong

[lexichronicle]

Piece = Inconel, Material = Titanium? Make yer minds up maties! It'll be Inconel anyway being a turbine disc.

Investment casting wouldn't be too expensive capital wise to get it running. Jewelers absolutely love the process because it's so easy to knock up a mould, then do tree, you wouldn't even need a tree for the disc. But I doubt you'll get usable surface quality. Full size turbine blades are press formed from blanks. And the heating parameters ludicrously precise - monocrystal structures

[MahdiEynian]

Spindle Speeds were 500-1200 rev/min. Maybe the video shouldn't be called high speed machining.

[maikeydii]

Half a million in machining time? Someone must be printing money with that kind of hourly rate. I know no machine shop which would be able to pull exess of 2000 USD or Euros per hour.

I would estimate that this part would cost around 30 - 40 000 euros to machine. Cost of fixtures and material on top of that.

[douro20]

This is why these parts are often cast and then machined instead of being machined out of a solid billet. With the amount of time necessary to machine one of these out of solid Inconel it is not practical to produce in that manner.

[graffitiballz]

depends on if it's just one piece, or hundreds of pieces, thousands of pieces. if a small number of pieces, machining is the way to go because of pattern making for the casting.

[graffitiballz]

wonder what the wax type material is they use to stabilize the blades

[douro20]

184 hours 21 minutes... that's more than a week

[douro20]

Wouldn't that be almost half a million dollars in machining time?

[graffitiballz]

yeah, and working 8 hour days, thats 4 and a half weeks!

[danway60]

@graffitiballz tbh tho m8, i think a company like this, making these types of parts would be running 24 hrs a day.

[douro20]

Italian machine...

[flouserve]

Vaya pedazo de mecanizado , además como el turron...del duro

[ravikumarjp]

Awesome program / tool path

can any one explain why plunge milling is chosen for roughing and its advantages, and name of the Roughing tool

[gulch1969]

Because if done right, plunge milling can remove stock really fast.

[nodnarbnoob]

because inconel is a tough material to cut in fact one of the toughest and the length to diameter ratio of the tool is unfavorable for side or slot milling, plunge milling generates about 70% less side force which is ideal for long tools to work effectively

[jtjoser]

@ravikumarjp

On such long tooling, plunging is preferably used because the forces applied on the tool are upwards and using the strongest axial cut direction of any tool. Long reach tools like these would chatter trying to maintain the same mrr (material removal rate) cutting against the tool... Side cutting with any tool puts more forces vs. cutting down parallel with the spindle. Does this make sense to you? I can’t clearly see the tool to tell you which one is it.

[dangunit69]

Dear God, 93 hours to machine!!!!

[nodnarbnoob]

i know thats unbelivable, i thought 45minutes was an eternity for cycle times!!

[edshift]

Any collision problems are down to bad cam->machine postprocessor programming.

Not saying it would be easy to write that post but the machine looks awesome.

Worth the bother.

[TheMSvids]

They have collision problems. The fixture is to high. To much compensation movements. Ceramic tools?No. Plunge cutting? No. Trochoid milling? No. To avoid fibrations they reduce feeds and speeds. There are swiss machines showing a much faster process.

[Abovegroundminer]

Cool and Precise! One hell of a program!

Macro Hell!

I would like to trade you 100lbs of mexican jumping beans for one of these machines!

P.S. I could swing the shipping if it's a even trade..

[Speed796]

That is awesome !!!!

[dgalvarez]

Amazing 5strs