SpinOffs

   

Increased Milling Capability and Capacity for Large 5-Axis Impellers

by Sean McDermott on Aug 30, 2019 9:19:33 AM

Concepts NREC has added two additional Hermle 5-axis mills in our shop, and we’re excited 

about the increased capabilities these new machines bring! In August of 2018 we received the 

first of these mills, a 2018 Hermle C52uMT.  Just recently, in May of 2019, we added a Hermle C42u


In addition to these new, state-of-the-art 5-axis Hermle mills, our shop utilizes a Mikron HSM600U, good for parts up to ~13” in diameter; a Hermle C40, which can mill parts up to ~20” in diameter, and a Mitsui Seiki HS5A-80, which can handle larger parts, up to ~32” in diameter.  We now have a full range of  5-axis mills capable of producing the most challenging parts from >1 inch up to over 39 inches in diameter.  

Valentine’s Day is February 14, and while some cynics refer to it as a “Hallmark holiday”, most people commemorate the day in some way. One of the biggest challenges is finding a card that perfectly captures the way you feel about someone, while also reflecting who you are.  Well, Concepts NREC has created some turbomachinery-themed Valentine’s Day cards for engineers. These fall into the Art end of our Art-to-Part Solution.

 

Temperature envelopes in the turbomachinery industry are constantly increasing as the state of the art evolves in pursuit of better performance. This means engineers need to design compressors with higher and higher exit temperatures, and turbines and nozzles with continuously increasing inlet temperatures. This rise in temperature greatly impacts the selection criteria for materials used. 

Flank Milling - How Hard Can It Be?

by Peter Klein on Jan 4, 2019 10:11:00 AM

 When designing compressors, engineers often use ruled-surface blades with the goal of making a shape that’s easily manufactured on a 5-axis machine.  Theses blades can be quickly machined in one pass by aligning the side of a cutting tool to the rulings. This process is often referred to as “flank milling.”  The alternative is to make many passes with the tool tip, a process known as “point milling”. For the right application, flank milling is often favored for shorter cutting times and better surface quality, but there are some caveats.

Reverse Engineering - Going from Part to Art

by Sharon Wight on Dec 7, 2018 9:12:37 AM

Have you ever needed to know the exact geometry of a compressor that has been running for years in your process plant? Perhaps you need to analyze how it would perform if the process fluid had to be changed to meet new government regulations. Or maybe there has been damage to the impeller and a complete mechanical analysis is required before a new one can be put into service. Eventually, everything, even well-designed turbomachinery, needs to be replaced or upgraded.

Avoiding the "Bad Day" in Aerospace

by Francis A. Di Bella, P.E. on Jul 6, 2018 9:17:04 AM

The AS9100 Certification identifies companies who have qualified to manufacture products for the Aerospace Industry.  Manufacturers who meet the extensive requirements of the AS9100 Certification have committed to maintaining quality assurances that ensure that their products are engineered, manufactured and maintained to provide the aerospace customer with a quality product. 

How Our Shop Slashed Their Roughing Time in Half

by Christos Maninos on Feb 22, 2018 2:44:53 PM

The guiding principle behind Concepts NREC’s Computer-Aided Manufacturing (CAM) software, MAX-PAC, is to simplify the task of creating efficient milling toolpaths for turbomachinery. Since we are also users of MAX-PAC in our manufacturing facility, we see first-hand how new features and functionality impact day-to-day operations. This was true with the release of our powerful 3+2 Roughing Module. After a year of using it, our machinists were amazed at the results. In almost every instance, they saw a 50% reduction in roughing cycle times, compared to the way they were doing 5-axis roughing. Wow!

 

Design Elements that Affect Machining Time in Turbomachinery

by Mark R. Anderson on Mar 9, 2017 2:55:26 PM

The primary options for laying out an impeller (i.e. flank milled versus point milled, open versus covered impellers, integral versus welded shrouds) determine the basic manufacturing process (see Manufacturing Methods Used for Turbomachinery for more info).  Beyond the basic layout, there are several other details of the design that can significantly affect manufacturability. They include: 

Manufacturing Methods Used for Turbomachinery

by Mark R. Anderson on Feb 22, 2017 12:42:53 PM

There are two dominant manufacturing methods used to produce turbomachinery parts – Casting and 5-axis machining. This blog will explore some of the applications and restrictions of these two methods.

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