Supplied in the UK by 2D CNC Machinery of Hinckley, this twin capability is just the start for the Mitsui Seiki Vertex 55X-H, as Robb Hudson, technology and business development manager of Mitsui Seiki USA explains: “Such has been the level of development of the single platform hybrid concept that it can be extended in the near future to integrate further nozzles for laser drilling and cutting, localised heat treatment, specific surface cleaning operations for a workpiece, as well as the drying of coolant residue.”
The Mitsui Seiki Vertex 55X-H combines traditional high precision Mitsui Seiki machine tool build with spindle-held combined ‘laser direct energy deposition (DED)/powder feed nozzles’. These nozzles are held in the toolchanger and loaded to the spindle when required. An advantage of the holding both cutting tools and the combined laser/powder head in the same spindle is that highest precision can be maintained (volumetric accuracy is claimed at sub-15 microns within the working envelope), meaning any number of changes between either process is possible.
Adds Hudson: “The process is under full adaptive control as the workpiece is being produced, thus ensuring that it is able to alternate back and forth between additive and conventional subtractive cutting cycles with the intended surface or feature being accurately maintained.”
A common adaptive programming language is employed to enable seamless changes between machining and additive manufacturing via (DED)/powder feed nozzles.
Exact control of positioning and deposition of powder is achieved through selectable laser beam profiles. Good surface finish is maintained and, in comparison to the use of the powder bed-based additive processes, significant cycle time reductions can be achieved and significant wastage of highly expensive materials avoided.
Typical application examples given by 2D CNC director David Holden are the repair of aerofoil parts such as high pressure blades, blisks and impellers typically used in the aerospace, power generation as well as oil and gas sectors. He explains: “As OEMs and designers are progressively introducing super-hard materials for their part production, hybrid technology such as this becomes ideal for cost-effective repairs or even part recovery. This can enable a possible scrap component to be re-engineered and brought back into a serviceable condition.”
The hybrid Mitsui Seiki Vertex 55X-H machine range has a working envelope of 550 to 750 mm in X, 600 to 800 mm in Y and 400 to 750 mm in Z. Spindle speeds are available between 15,000 and 30,000 rpm and the machine incorporates an integrated coolant system to suit both wet and dry production cycles.
