In one case involving the machining of a compressor disc, by eliminating the traditional initial broaching operation and using only milling tools, the part could be produced four times faster and with a surface finish of Ra 0.19 micron. Another example showed how the use of ceramic tooling can help cut production times of Inconel 718 blisks from the conventional 35/40 hours down to just 10 hours.
The demonstrations not only highlighted the ability of Starrag machining centres, but they also showed the extent of cooperation between Starrag and Walter to develop special-purpose tooling solutions.
Attended by almost 200 delegates from 80 or so aerospace OEMs and first tier suppliers from across the world – including as far afield as Korea and China – the two-day programme addressed every machining demand that visitors face, and presented opportunities for everyone involved in aerospace and energy machining to generate substantial savings and therefore rewards.
That such rises in machining efficiency and effectiveness has an obviously profitable future was highlighted by the event's keynote speaker, Yang Hong, vice general manager of AVIC International Aero Development Corporation of China. In his presentation on 'Trends and the future of equipment import to the Chinese aviation industry', Hong stated that China will spend $300 billion on civil aircraft alone over the next ten years. Adding that the nation's investment levels in production equipment look set to continue to rise, he also pointed out that China is equally enthused about the potential for its aircraft OEMs and suppliers to utilise more fully the machine tools they already have in place – including by applying automation.
Demonstrations at the Turbine Technology Days followed along with this theme, including those on the Starrag LX051 with robot load/unload and the bar-fed Starrag LX021 that was producing small blades in a single set-up.
Another relevant demonstration was of the adaptive machining software, in this case for aerofoil repairs, from Starrag Group company TTL. TTL software can machine and blend complex 3D components and features automatically where geometrical differences exist between one component and the next. The software is an effective replacement for what is traditionally a labour-intensive/manual process and, in addition to being consistent all day, every day, the use of the software also produces time savings of at least 30% on each blade.
