Turbomachinery Roughing | Concepts NREC

Roughing Strategy for MAX-PAC^™

Concepts NREC's optional 3+2 Roughing Module enables roughing out of impellers using 3-axis algorithms, keeping a constant tool vector. This strategy optimizes the toolpath to provide constant cutting load, making it suitable for high speed machining. This is extremely helpful for large (>0.5 m) diameter impellers and/or hard materials where roughing using the 5-axis strategies of MAX-PAC is less efficient.

MAX-SI Advantages

One-piece shrouded impellers have many advantages over parts produced as an assembly of separate hub and shroud components (or even individual blades), including less raw material and fewer manufacturing process steps. Also, integrally shrouded components avoid heat distortion and have stronger shroud joints compared to fabricated assemblies.
Advanced Capabilities

MAX-SI includes strategies for pocket roughing, plunge milling, box passes for finish/semifinish, and flow-direction finish milling.

One-piece shrouded impellers have many advantages over parts produced as an assembly of separate hub and shroud components (or even individual blades), including less raw material and fewer manufacturing process steps. Also, integrally shrouded components avoid heat distortion and have stronger shroud joints compared to fabricated assemblies.

MAX-SI includes strategies for pocket roughing, plunge milling, box passes for finish/semifinish, and flow-direction finish milling.

Better, Faster, Cheaper

Manufacturing turbomachinery components is often a challenge due to hard materials, thin blades, tight tolerances, smooth surface- finish requirements, or difficult tool access. Concepts NREC’s MAX-PAC CAM software was built from the ground up to address these challenges. MAX-PAC enables users to produce high-quality components in less time and at lower cost. Compared to other general CAM tools, MAX-PAC is faster to learn, easier to use, and requires less programming and machining time. Its choice of cutting strategies ensures that each client has a solution tailored to their specific milling requirements. The most important attribute of MAX-PAC, however, is its ability to produce higher-quality turbomachinery components.

MAX-PAC Advantages

Specialized for turbomachinery production
Easy and fast to learn
Supports a broad selection of tool geometries
Faster machining times with optimized cutting strategies
Smooth 5-axis toolpaths for high-speed milling
Collision-free toolpaths for difficult geometries
Superior surface finish and tight tolerances using a patented flank- or point-milling approach
Produces high-quality parts that don’t require hand finishing or other reworking

Collision Avoidance

Parts are getting more complicated and manufacturing them can be challenging. MAX-PAC automatically checks the feasibility of machining your part as soon as you program in the tool, holder and geometry. Our patented collision avoidance algorithm quickly determines a smooth, safe trajectory for both the tool and holder through the pocket, or gives a warning if one can’t be found. This saves you time and money by avoiding a lot of simulations and/or test cutting.

Other CAM systems use individual points based on the part's geometry to create a collision-free toolpath. MAX-PAC calculates an entire collision free zone and then determines the smoothest path through that zone to produce the best part in the shortest amount of time. This approach also enables MAX-PAC to machine parts other software can't.

Other CAM systems use an approach that results in a "jerky" motion as seen here. Note how the tool flip-flops around the lead and trail edges:

MAX-PAC's approach results in a much smoother machine motion, especially as the tool goes around the lead and trail edges:

For example, we have a large OEM customer who was trying to machine an impeller. The software they were using at the time could not find a toolpath that would enable them to manufacture the part as designed. After months of trying, they approached Concepts NREC with their problem. We were able to deliver a workable toolpath the next day. Needless to say, the customer switched software!

Software Highlights

With MAX-5, you can machine open impellers with a higher quality finish, faster!

Software Highlights

MAX-PAC Add-On Modules

MAX-PAC offers several different add-on modules that are focused on specific milling needs. You can purchase any combination of modules to meet your specific machining requirements.

MAX-5 - Flank Milling

MAX-AB - Point Milling

MAX-SI - Integral Shroud Milling

MAX-SB - Single Blade Milling

3+2 Roughing Module

Postprocessing and Simulation

MAX-PAC Add-On Modules

MAX-PAC offers several different add-on modules that are focused on specific milling needs. You can purchase any combination of modules to meet your specific machining requirements.

MAX-5 –Flank Milling

MAX-AB – Point Milling

MAX-SI - Integral Shroud Milling

MAX-SB – Single Blade Milling

3+2 Roughing Module

Postprocessing and Simulation

Software Support

Customer-driven Improvement

AxCent has been continuously improved with annual releases since 1983. Nearly two hundred licenses shared by nearly four hundred users worldwide make AxCent the most mature and robust turbomachinery design software available today. Each year, the most requested features from Concepts NREC’s formal ballot process are incorporated into the new AxCent release.

Technical Support

Our support staff in North America, Europe, and the Far East includes experienced turbomachinery designers. Our software maintenance plan, Agile Products Support (APS), features traditional software upgrades, a help line, and regular design reviews conducted by our engineering staff, who also teaches our renowned turbomachinery courses.

Documentation

Documentation features make AxCent easy to use and include comprehensive HTML HELP plus step-by-step tutorials. User guides for designing radial and axial machines include Designing Axial Machines With AxCent and Designing Radial Machines With AxCent. Both guides are available in print or in searchable PDF format.

Benefits

3+2_MAX-PAC

Achieve faster roughing using 3-axis toolpaths at an arbitrary angle (3+2)
Provides consistent cutting conditions enabling greater feed rates as well as longer tool and machine life.
Helical entry provides smooth engagement of the cutter and eliminates the need for drilling
Save 5-axis machining time by performing roughing operations on 3-axis machines
Save programming time by calculating roughing toolpaths together with finish toolpaths in the same software package on the same geometry
Reduce software costs by eliminating the need for a separate package to calculate 3+2 roughing toolpaths

3plus 2 roughing

Benefits

Achieve faster roughing using 3-axis toolpaths at an arbitrary angle (3+2)
Provides consistent cutting conditions enabling greater feed rates as well as longer tool and machine life.
Helical entry provides smooth engagement of the cutter and eliminates the need for drilling
Save 5-axis machining time by performing roughing operations on 3-axis machines
Save programming time by calculating roughing toolpaths together with finish toolpaths in the same software package on the same geometry
Reduce software costs by eliminating the need for a separate package to calculate 3+2 roughing toolpaths

3+2 Roughing Brochure

3+2 Roughing enables turbomachinery roughing out of impellers using 3-axis algorithms, keeping a constant tool vector. This strategy optimizes the toolpath to provide constant cutting load, making it suitable for high-speed machining. This is extremely helpful for large (>0.5 m) diameter parts and/or hard materials where roughing using the traditional 5-axis strategies of MAX-PAC is less efficient.

Download Brochure

Find Your Rep

North America

Mr. Don Roberson

Phone:

Email: DRoberson@conceptsnrec.com

South America

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