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Blisk Five-Axis High-Feed Milling

C.B. Ferrari has developed a new 5-axis machining process for blisks based on high-feed milling (HFM).

"During HFM, the majority of the cutting forces are directed back towards the spindle, parallel to the cutting tool, with only a small amount of force acting perpendicularly," said a company spokesperson. Directing the cutting forces axially, into the spindle column of the machine, provides the greatest stability, and allows HFM to be particularly effective for processing the long, deep cavities required for blisk manufacturing.

Additionally, HFM allows for increased accuracy to near-net shape utilizing smaller step downs at high feeds, thus reducing large scallops. This makes the finishing process more efficient.

The ML45 is a 5-axis direct-drive portal machining center specifically designed for achieving high surface quality and processing efficiency. The process has been developed using the company's TS85 software, a CAM dedicated to complex 5-axis airfoil machining and used primarily for turbine component manufacturing applications.

The ML45 machine layout includes a vertical 18/23 Nm, 28,000 RPM HSK-E40 spindle and a two-axes direct-drive rotary-tilting table, which make it suitable for the HFM processing of titanium blisks up to 250 mm in diameter. The wear-less direct-drive technology allows for enhanced reliability.

The ML45 design allows for increased chip evacuation and easy automatic part loading/unloading integration. It is suitable for simple workpiece pallet changers or complex Industry 4.0 compliant flexible manufacturing cells.

ML45 features:

  • XYZ axes: 320 mm
  • B-axis (tilting): +135°/-100°
  • C-axis (rotary): 360°
  • Rapid traverse: 60m/min
  • Spindle: 18/23 Nm - 28,000 RPM - HSK-E40
  • Max. workpiece size: 280 mm D x 200 mm H
  • Max. payload: 30 kg
  • ATC capacity: 56.

C.B. Ferrari produces 5- and 6-axis machines, automated systems and turn-key milling and laser solutions.

For more information contact:

C.B. Ferrari Inc.

22179 N. Pepper Road

Lake Barrington, IL 60010-2357


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