turbine blades - KYOCERA UNIMERCO

Optimisation models
TURBINE BLADES
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Complete tooling programmes
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Customised tools
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To o l m a i n t e n a n c e
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To o l m a n a g e m e n t s y s t e m s
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Tr a i n i n g a n d e d u c a t i o n
UNIMERCO TOOLING SOLUTIONS FOR THE AEROSPACE
AND POWER GENERATION INDUSTRIES
UNIMERCO INTRO
Optimisation models
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Complete tooling programmes
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Customised tools
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To o l m a i n t e n a n c e
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To o l m a n a g e m e n t s y s t e m s
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Tr a i n i n g a n d e d u c a t i o n
OPTIMISED PRODUCTION
UNIMERCO
– your full-service tooling partner
Norms and ECR – guarantee of identical
tools, whether new or RE•NEW®
UNIMERCO offers a complete tooling programme for machining
aerospace metals and fibre composites. As the choice of tool is
always based on a cost-benefit assessment, the solution often
includes standard, customised carbide and diamond tools. This
allows you to get the best total solution from one source, thus
reducing your supplier base.
All UNIMERCO companies utilise integrated CAD/CAM for design
and production. The solution is part of the guarantee of 100%
identical design and production within UNIMERCO. All tools have
been designed in accordance with UNIMERCO norms (a norm is an
instruction that controls the geometry, measurement and manufacturing process). The norms are developed and maintained centrally
and subsequently distributed to all companies in the UNIMERCO
GROUP via UNIMERCO’s central server.
High performance tooling solutions
To machine a component at the lowest possible costs, you need
the best possible combination of machinery, machining parameters
and tooling solutions. Therefore, we analyse all aspects of the production process involving cutting tools and systematically optimise
them. Subsequently, our tool developers define the optimum tooling solution customised to fit your requirements. Often, we are able
to implement a solution which reduces the number of tools necessary for a certain operation or simplifies the process, thus considerably reducing tooling costs and machining time.
For this specific purpose, the central programme database secures
that all CNC-controlled machines in all companies of UNIMERCO
GROUP use the exact same machining data. All CNC machines are
from the same manufacturer and are also calibrated to a master
machine. Programmes are automatically deleted from each machine immediately after use.
All tools are developed and manufactured utilising the latest technology. The optimum tooling solution often includes the unique geometries developed by UNIMERCO which helps to ensure extreme
accuracy and tight tolerances. This means that tools can be run
at extremely high cutting speeds in balanced conditions utilising
the full capability of machine tools and maximising metal removal
rates.
The results are short design times, high accuracy and repeatability
and high-capacity utilisation resulting in fast deliveries. The benefit
is that any tool will perform the same whether new or RE•NEW®
guaranteeing you process reliability and high performance.
In addition, we have created an electronic drawing database which
offers version management, search options and traceability.
RE•NEW® – regrinding and repair
of all PCD tool brands
Reliable and profitable production demands professional tool maintenance. RE•NEW® is UNIMERCO’s full-service repair and regrind
service of own tools and all other tool brands. The RE•NEW® concept ensures that high productivity, function, and tool life are maintained throughout the life span of the tool – with a performance
guarantee. This means that you can confidently run any UNIMERCO
RE•NEW® tool in production at full speed without compromising, as
you would for competitors’ re-ground tools.
We call it RE•NEW® because the tool will perform as well re-ground
as it will when it is new – if not better!
Some images courtesy of Quadrant Picture Library
Optimisation models
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Complete tooling programmes
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Customised tools
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To o l m a i n t e n a n c e
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To o l m a n a g e m e n t s y s t e m s
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Tr a i n i n g a n d e d u c a t i o n
COMPLETE TOOLING SOLUTIONS
Test facility
Safety stock and tool management
To stay ahead of the field, UNIMERCO has set up a 5-axis machining
centre for performance testing of new tools using both traditional
lubrication and minimum quantity lubrication (MQL). For instance,
the tools are tested for function, runout accuracy, tool life, and
UNIMERCO also establishes the optimum machining parameters
for given applications.
If so desired by the customer, UNIMERCO offers to establish a
safety stock for urgent deliveries. In return, the customer undertakes to buy the tools in question within a fixed period of time. In
additon to this we run fully automated tool management with crib
systems to larger customers with a full reporting system to help
managers with financial production control.
Research and development
Implementation
UNIMERCO believes that the way forward is investment. As well as
extensive investment in plant and machinery, heavy investment is
made each year in developing new tool solutions for new materials and applications. UNIMERCO is currently undertaking research
projects with major universities around the world into cutting solutions for the latest materials, some of which are seen today as ‘impossible to cut’. Working with UNIMERCO will give you access to the
latest technology and help you increase your productivity through
performance cutting solutions.
In our opinion, tool delivery is just part of the total solution. The
most efficient production situation is achieved only if the tool is
used correctly. Thus, our optimisation experts will assist during this
phase with advice concerning cutting para­meters, cooling, production reliability and will optimise production for you.
Fast delivery
Why a partnership?
Long-term improvement of competitiveness demands a serious
and permanent cooperation in which both parties work together to
improve productivity. That’s why UNIMERCO is the preferred tooling
partner for the aerospace industry.
The standard delivery time on solid carbide is 2-3 weeks and 4-6
weeks for PCD. A complete programme of standard mills, drills,
countersinks, reamers and spindle nose tooling is available ex.
stock (see page 19). The manufacturing capacity in Denmark (2
sites), the UK and USA, enables us to carry out fast deliveries of
tools. This means that you carry less inventory and ultimately have
less cash tied up in stock.
UM SOP™
(Systematic Optimisation of Production)
UM SOP™ is a method and optimisation tool which is applied in
order to reduce your production unit costs. UNIMERCO’s sales engineers evaluate customer processes and make constructive suggestions, showing how a new process is implemented and predicting
the cost savings. Over time, the optimisation data is collected and
presented to senior managers to show the projects that have been
optimised and the financial benefits to the company. The system
maximises the efficiency of both UNIMERCO’s time – and yours. UM
SOP™ is consultancy and is there to increase your productivity and
ultimately increase your profits.
BLADE MACHINING
Optimisation models
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Complete tooling programmes
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Customised tools
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To o l m a i n t e n a n c e
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To o l m a n a g e m e n t s y s t e m s
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Tr a i n i n g a n d e d u c a t i o n
FULL RANGE OF CARBIDE TOOLING SOLUTIONS
AIR FOIL TO PLATFORM TRANSITION
AIR FOIL
Lollipop, ballnose and taper
ballnose solutions. Options
available for high speed machining and conventional 3-5
axis machining.
Ballnose, torus and barrel
form tools are designed to
maximise step over and
therefore maximise surface
generation rates.
SNUBBER
Taper ballnose and
lollipop designs for conventional and high speed
machining.
ROOT
Brazed and solid carbide solutions for rough
and finish machining.
Cutter root form profile
measuring reports are
available.
PLATFORM
1
Custom designed parallel and conical tools for
maximum performance
when machining at up to
400m/min.
CASE STORY
Optimisation models
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Complete tooling programmes
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Customised tools
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To o l m a i n t e n a n c e
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To o l m a n a g e m e n t s y s t e m s
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Tr a i n i n g a n d e d u c a t i o n
SLOTTING A ’V’ NOTCH IN A BLADE ROOT
High-performance roughing of Jethete
stainless steel using a conical NTS-HPC
cutter
The customer needed to slot mill a 40º included angle ‘V’ feature
in the root of a turbine blade. His old method was to use a modified
2 flute uncoated HSS slot drill. The 40º angle was put on by a local
grind shop.
The UNIMERCO tool produced the slot 6 times faster.
The example shown is one tool from a total optimisation carried
out by UNIMERCO (UM SOP™ – Systematic Optimisation of Production).
The machining costs were reduced by 60% and the consumable
tool cost reduced by 37% for EVERY BLADE PRODUCED!
The UNIMERCO solution was a 4 flute, C7-coated solid carbide conical endmill with NTS-HPC roughing geoemtry.
OLD METHOD NEW METHOD
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Vc = 25m/min
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Vc = 50m/min
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Fz = 0.05mm
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Fz = 0.075mm
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Teeth = 2
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Teeth = 4
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Feed = 40mm/min
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Feed = 240mm/min
Uncoated HSS
modified slot drill
C7 coated
solid carbide
SAVINGS
As well as the tool optimisation shown above, UNIMERCO also looked at the complete manufacture of this blade and optimised the
remaining tools.
The economical comparison shows the tool and machining costs for
the original process and UNIMERCO’s optimised process.
The result of this is that 13 tools were reduced to 9 and the productivity was considerably increased.
MACHINING COSTS REDUCED BY 60%
CONSUMABLE TOOL COSTS REDUCED BY 37%
SURFACE COATING
Optimisation models
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Complete tooling programmes
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Customised tools
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To o l m a i n t e n a n c e
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To o l m a n a g e m e n t s y s t e m s
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Tr a i n i n g a n d e d u c a t i o n
C7 – NANOCOMPOSITE COATING
Application areas – material examples
Hardened steel
Stainless steel
Cast Iron
Aluminium (Si > 12%)
Ni-based alloys
The C7 coating is the result of a new patented coating technology which
makes it possible to use nanocomposite coatings on cutting tools. The advantages are noticeable, as the C7 coating increases tool life for high performance tools considerably. Moreover, the high heat resistance of the coating
makes it possible to increase the cutting speed, thus substantially increasing
the productivity.
Typical application areas
Titanium
The best results are obtained in high performance applications (hard-to-machine materials), fully utilising the hardness and temperature resistance of C7.
SPECIFICATIONS
C7
New revolutionary nanocomposite coating
New coating equipment allows deposition of hard and tough nanocomposite tool coatings. Nanocrystalline grains are embedded in an amorphous
matrix which creates an enormously compact and heat resistant structure with
increased hardness.
The extreme heat resistance means that the C7 coating maintains its stability
and superior properties at temperatures of up to 1,100o C. In fact, the hardness of above 40 GPa is retained until 1,000o C, and then declines slightly to
35 GPa at 1,100o C. This makes it possible to increase feeds and speeds to
unprecedented levels, thus boosting productivity.
State-of-the-art coating centre in the UK
At all UNIMERCO manufacturing sites, we have in-house coating centres and
highly skilled personnel to ensure the optimum surface treatment. We optimise the performance of a wide range of tool types using a variety of coatings.
In the UK, our coating facility is located in our newly-built factory in Lichfield.
Gain a competitive edge from the latest technology
A comparative test of four different coating types
– with C7 as a clear winner!
The C7 nanocomposite coating gives you the opportunity to optimise your
production by taking advantage of the superior performance offered by C7coated cutting tools. Coating is only a part of the services we offer. Contact us
and learn how a cooperation with UNIMERCO can contribute to considerably
reducing your production costs.
DOUBLE TOOL LIFE WHEN ROUGHING JETHETE TURBINE BLADES
100-400% EDGE LIFE INCREASES IN TITANIUM APPLICATIONS
C7-COATED ENDMILLS OUTPERFORM BUTTON MILLS
6
STANDARD PROGRAMME
Optimisation models
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Complete tooling programmes
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Customised tools
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To o l m a i n t e n a n c e
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To o l m a n a g e m e n t s y s t e m s
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Tr a i n i n g a n d e d u c a t i o n
INTRODUCTION TO THE UM CATALOGUE
Catalogue structure
UNIMERCOs core business is the manufacture and RE•NEW® of
special tools to optimise customers production. In addition to this,
UNIMERCO offers a complete tooling programme. This is available
in the UM catalogue.
The UM catalogue is based on the UM CONCEPT™ and includes a
number of products and services aiming at reducing unit costs and
improving competitiveness.
The catalogue is user-friendly and symbols have been used extensively to explain tool properties. All necessary information on
recommended cutting data and material classes has also been included on the pages, where relevant.
We have aimed at making the catalogue as easy to use as possible but choice of tool and cutting data will always depend on the
specific situation.
Please contact one of our technical sales engineers who will help
you choose the right tools and optimum cutting parameters.
CHAPTERS OVERVIEW
Milling
Surface coating
• HSS and HSS PM end mills
• Standard and high performance carbide end mills
• Customised milling cutters
• UNIMERCO’s tribology centre
• Coating of cutting tools
• Coating of non-cutting tools
Drilling
Toolholding systems
• High performance carbide twist drills
• High performance carbide straight flute drills
• High performance carbide three flute drills
• Complete toolholding programme
• Collet chucks/hydraulic chucks/
shrink fits
• Systems from Nikken and Schunk
Thread cutting tools
Tool maintenance
• HSS and HSS PM taps
• HSS fluteless taps
• Thread milling cutters
• Dies
• RE•NEW® carbide tools
• RE•NEW® and re-tip PCD tools
• RE•NEW® veined PCD tools
Countersinks and reamers
Tool management
• HSS countersinks
• Carbide countersinks
• HSS reamers
• Carbide reamers
• Tool lockers
• AutoCrib dispensing stations
• UNI•SERVICE
Diamond tools
Training and education
• PCD milling cutters
• PCD drills
• PCD special tools
• Standard courses
• Special courses
• Production analysis
• Theme days
UNIMERCO GROUP
UNIMERCO is an international manufacturer and distributor of tooling
solutions with companies in Denmark, UK, Germany, USA, China,
Sweden, Norway and the Czech Republic. UNIMERCO was established
in 1964 and today has around 600 employees.
The Group works to increase the efficiency and cost savings of our
customers by means of optimum tooling solutions and services. We
service a number of industries, including automotive, aerospace,
telecommunications, general machining, food processing, window and
furniture.
DENMARK
UNIMERCO A/S
Drejervej 2
DK-7451 Sunds
Tlf. +45 97 14 14 11
Fax +45 97 14 14 86
umdk@unimerco.com
CENtRAL EUROPE
UNIMERCO, s.r.o.
Vídeňská 102
CZ-619 00 Brno
Tel. +420 547 426 535
Fax +420 547 426 536
umcz@unimerco.com
UNIMERCO GROUP
POLAND
UNIMERCO Sp. z o.o.
ul. Rynek 7
PL-50-106 Wrocław
Tel: +48 71 722 0030
Fax: +48 71 722 0031
umpl@unimerco.com
UNIMERCO is an international manufacturer and distributor of tooling
solutions with companies in Denmark, UK, Germany, USA, China,
NORWAY
USA
DENMARK
Sweden, Norway
the Czech
Republic.
established
UNIMERCO
AS UNIMERCO wasUNIMERCO
Inc.
UNIMERCO
A/S (UM and
DANDIA)
Ulvenveien 90
6620 State Road
Erik Husfeldts Vej 7
in
1964
and
today
has
around
600
employees.
NO-0581 Oslo
Saline, MI 48176, USA
DK-2630 Taastrup
Tlf. +47 22 72 06 02
Tlf. +45 36 72 12 52
22 65 09 80
Fax
36 72works
12 92 to increaseFax
The +45
Group
the+47
efficiency
and
umno@unimerco.com
dandiadk@unimerco.com
Ph. +1 734 944 4433
UNIMERCO GmbH
Mauserstraße 30
DE-71640 Ludwigsburg-Ossweil
Tel. +49 (0)7141 6434 755
Fax +49 (0)7141 6434 756
umde@unimerco.com
UNIMERCO Ltd.
Nanscawen Road, Fradley
UK-Staffordshire WS13 8LH
Ph. +44 (0)1543 267 777
Fax +44 (0)1543 267 778
umuk@unimerco.com
UNIMERCO Inc Southeast
13850 Ballantyne Corporate
Place, Suite 500
Charlotte, NC 28277
Ph. +001 704-887-3440
Fax. +001 704-887-3441
ummi@unimerco.com
SWEDEN
UNIMERCO AB
Sagaholmsvägen 9
S-553 02 Jönköping
Tel. +46 (0)36 34 46 00
Fax +46 (0)36 31 32 00
umse@unimerco.com
CHINA
UNIMERCO Ltd.
Wuxi Representative Office
Room 205, No. 2-1
North Changjiang Rd.
Wuxi, Jiangsu, 214028
P.R.China
Ph. +86 510 8521 0088
Fax +86 510 8521 9988
umcn@unimerco.com
CHINA
UNIMERCO Ltd.
Beijing Office
Room 2015
Lianri International
Apartment No. 18
Nan Lang Jia Yuan,
Chaoyang District,
Beijing, 100022
P.R.China
Ph. + 86 10 6567 9745
Fax + 86 10 6567 9774
umcn@unimerco.com
UNIMERCO 06.05 064_1025_PM_ML-UK
Faxof+1our
734 944 4432
cost savings
ummi@unimerco.com
customers by means of optimum tooling solutions and services. We
service a number of industries, including automotive, aerospace,
telecommunications, general machining, food processing, window and
furniture. - AUStRIA
GERMANY
UNItED KINGDOM
USA