Delcam will promote its wide range of software and services for the aerospace manufacturing and MRO industries at AIRTEC exhibition to be held in Frankfurt from 28th to 30th October. These services can help aerospace companies whenever they need to increase productivity, to reduce lead times or to improve quality and consistency.
The range of support from Delcam Professional Services is mainly intended to help any company whose own engineering resource is needed to maintain its existing operations. The services provided can vary from supplying extra design and programming resources when existing staff are overloaded, through to developing dedicated software to automate existing manufacturing methods or to establishing completely new turn-key processes for the manufacture of novel designs.
Recent developments using Delcam software include the programming, with Delcam’s unique adaptive machining technology, of a new hybrid machine from Hamuel Maschinenbau for the remanufacturing of high-value metal components, such as turbine blades, and a novel five-axis machining method, programmed with the company’s PowerMILL CAM system, for the creation of "fir-tree” profiles in components for turbo machinery.
The Hamuel hybrid machine combines five technologies in one unit – five-axis CNC milling, laser cladding, robot polishing, inspection and laser marking. Any of these processes can be combined, as required by the particular project. The equipment costs only a fraction of the price of a multi-machine repair cell, as well as saving on floor space.
Using a hybrid machine, it is possible to remove the damaged area of a turbine blade by milling off the worn material and then build the material back up using the cladding technology. A second machining operation, using high-speed five-axis milling, then produces the final shape, with a smooth transition between the original part and the new material. Polishing and laser marking can be undertaken to complete the component, if required. In-cycle part inspection, using Delcam’s adaptive machining software, provides feedback to orientate the parts, assess defects, and ensure accuracy throughout the various stages.
The novel method for the creation of "fir-tree” profiles was developed in partnership with Iruba, a German provider of engineered solutions, and machine-tool manufacturer Hermle. It allows these complex shapes to be produced on milling machines, such as the Hermle C60 five-axis machining centre, rather than having to use specialist broaching equipment.
The use of PowerMILL’s trochoidal strategies to program the operation gives a number of benefits, in particular high material removal rates with lower, and more consistent, cutting forces.
These latest projects continue a trend that has seen Delcam systems used, at some stage, on virtually every major aircraft programme in recent years. The company’s customers have undertaken projects in all the various areas that go towards producing a successful aircraft, from developing more fuel-efficient engines, to manufacturing airframe components more effectively, and even in designing more comfortable and more attractive interiors. They have worked on all scales of project, from the manufacture of components for UAVs and helicopters up to the production of engines and airframes for the largest passenger and transport aircraft.
Delcam also supports a large number of MRO operations. These companies use Delcam systems to enable the fast, efficient repair or replacement of damaged components. By minimising design and manufacturing times, while maintaining the highest levels of quality, repairs can be completed as quickly as possible, so minimising the time-on-ground of the aircraft.
