MAX-5™
Create 5-Axis N/C Machining Instructions for Flank Milling Complex Turbomachinery Components
MAX-5 is an interactive CAM system to create 5-axis NC machining instructions for flank milling of ruled-surface turbomachinery components. Typical applications include centrifugal compressors, pumps, inducers, turbochargers, stators, fans, radial-inflow turbines, expanders and torque converters.
MAX-5 Advantages
- Produce high-quality parts
- Easy and fast to program
- Obtain superior surface finish and meet tight tolerances with patented flank-milling approach
- Reduce machining time with specialized cutting techniques
- Developed exclusively for turbomachinery production
Turbomachinery components are often considered to be challenging components to manufacture. They can be made from hard materials, have thin blade sections, require slender cutters, and often have tight tolerances and smooth surface finish requirements. These components often have complex geometry that mandates 5-axis manufacturing solutions. Aerodynamic designs do not always provide complete descriptions of all geometric features and require the CAM software to construct edge details, complex fillet surfaces, or other blade constructions.
High-speed machining is often used to reduce cycle times. This approach requires careful process control and smooth machining instructions.
MAX-5 is a sophisticated software system to bridge the gap between advanced component design and cost-effective manufacturing. MAX-5 is a technical and market leader that is used worldwide to produce all types of turbomachinery components, in all materials and sizes. It possesses the required technology and enables users to effectively produce turbomachinery and gas turbine components.
The software emphasizes productivity, both for manufacturing engineers and machine tools. Programming menus are structured to avoid programming mistakes. Family-of-parts concepts facilitate the programming of shroud cuts, diameter trims, scale models, and other variants of a baseline design. Typical programming time is measured in hours, not days or weeks as required by general purpose CAD/CAM software.
Dramatic cost savings can be realized using ruled-surface designs and production with a flank-milling process. This process allows the entire blade surface to be finished with one pass. The alternative point-milling process may require 80 or more finish passes to leave a suitably small cusp height between consecutive passes.
MAX-5 User Benefits
The user interface guides the programmer to enter machining operations, and specify parameters for each operation. Input values are checked for validity and on-line help is available. Inputs are stored and can be used for similar applications.
Geometric Modeling
MAX-5 can be applied to a wide range of turbomachinery components including centrifugal and axial bladed components. The software can scale components, rotate coordinate systems, and create many turbomachinery-specific design constructions as required, such as leading and trailing edge shapes, constant and variable-radius fillets, and blade thinning.
Automatic Tool Selection
MAX-5 can select cutter sizes for each operation from a cutter catalog, or confirm user-specified cutters. The cutters are checked against specific parameters such as operation depth and clearance offsets. MAX-5 selects the largest cutter that will fit in the specified blade pocket. Turbomachinery components typically require high aspect-ratio cutters. Cutters selected by the program have increased stiffness and optimize material removal.
The program also has a patented interference detection and avoidance module. This ensures the calculation of non-interfering, smooth machining instructions.
Graphical simulation
P3MAX™ is used to render blade surfaces and show dynamic tool motion. Tool tip, tool center, path points, and cutter vectors may be displayed. P3MAX animation uses a fixed-part reference or a patented fixed-cutter reference. Vericut® software verifies cutter paths by showing material removal on-screen. Vericut's OptiPath® module can override programmed feedrates based on cut volume or to maintain a constant chip load.
Machine Compatibility
Standard output from MAX-5 contains APT GOTO commands that are compatible with commercially available postprocessors. Direct postprocessors can also be developed and include custom commands for each user. G-code commands from developed postprocessors can also be read directly into P3MAX.
MAX-5 Technical Specifications
Input Formats
Accepts surface descriptions from many engineering software including CCAD®. Most formats include tables of coordinates for each blade surface. A file conversion module accepts other blade surface descriptions. A NURBS surface format is also available. Custom interfaces can be developed upon request. Other optional inputs include splitter geometry, hub and shroud contours, edge details, and variable-radius fillet geometry.
Units
For compatibility with most milling machines, output values are specified in inches or millimeters. Input values can be scaled to produce data in these unit systems.
Cutting strategies
There are many roughing strategies available to support varying preferences. The user may select among many different depth, length, and width methods. For example, large diameter cutters can be used in exducer regions, where the width between blades is typically larger than in inducer regions. Or roughing depth levels may be offset from the shroud to reduce the path length of deep operations, which use the longest cutters. Plunge milling techniques are also available.
Feedrates are automatically changed for slot cuts, peripheral cuts, and transitional air movements.
Hub finish operations use either a longitudinal or triangulated cutter path template.
Blade finish operations use the flank-milling process to produce a smooth surface finish. Patented undercut reduction techniques significantly reduce mathematical flank-milling undercut errors.
Many edge cutting strategies support flank- and point-milling, as required by the edge geometry or user preferences. Other specialized operations cut chamfers at blade tips or can produce slotting instructions along the centerline. These operations support subsequent shroud-attachement processes.
Output Files
The software creates part programs for each machining operation. These programs produce one blade and one pocket. A main program is developed by the user to sequence operations, link programs, and increment the instructions to adjacent pockets.
Other files are produced to export geometry to CAD/CAM software, graphical simulation programs and inspection machines. A listing file is produced to document a program run and record program calculations, estimated path lengths and cycle times, and undercut reports. A successive-runs file stores program parameters and can be used to rerun a particular job or as a template for a similar job.
CPU Requirements
MAX-5 operates on PC platforms with Windows NT and 2000 operating systems and a minimum of 64 MB RAM. Distribution is by CD-ROM or ftp.
Training
Two days of training at Concepts NREC is included with a MAX-5 license. Off-site training may also be arranged. Training covers geometry preparation, use of the software, and analysis of output data. Users may include their case for discussion and analysis during training.
Support
Concepts NREC provides basic telephone support and installation assistance at no additional charge. Users are encouraged to purchase our AGILE™ Products Support service, which includes 24-hour response to support inquiries, software updates, and assistance with difficult problems.
MAX-5, P3MAX are trademarks of Concepts ETI, Inc.
CCAD is a registered trademark of Concepts ETI, Inc.
Vericut and Optipath are registered trademarks of CG Tech, Inc.
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