GF Machining Solutions Develops Next Generation Wire EDM Machine
With the goals of increased flexibility and reduced maintenance in mind, GF Machining Solutions developed its next generation CUT S 400 Dedicated wire electrical discharge machine (EDM) that improves the overall production of aerospace jet engine turbine disks, in particular for cutting their fir tree blade patterns. With advanced features and capabilities, the new machine allows manufacturers to cut a wider range of turbine blade diameters and do so with fewer production interruptions due to typical EDM setup and maintenance issues.
While dedicated is in its name, the CUT S 400 Dedicated gives manufacturers the flexibility to create the complete range of popular jet aircraft engine disk diameter sizes with one machine. Geared toward those disks made from nickel-based or waspaloy alloys used in the “hot” critical side or the “cold” non-critical side of an engine, the new wire EDM handles disks measuring from 160 mm up to 680 mm in diameter.
The machine can accommodate this wide range of disk sizes thanks to its new, more robust rotary/tilt axis that easily manages heavier part loads without risk of deflection. A new additive manufactured smaller lower head nozzle size also provides additional room for smaller disk diameters while allowing for the use of various types of wire and wire guide diameters.
According to Eric Ostini, Manager of Business Development at GF Machining Solutions, the aerospace industry continues to design and develop jet engine disks, but there remain legacy engines still requiring replacement parts. “With that said, the CUT S 400 Dedicated increases the range capability for supporting not only existing disk designs but also for those older ones still in use,” he said.
Besides increased part size flexibility, many of the machine’s new technological advancements make required maintenance easier and less frequent, which in turn, reduces the amount and duration of non-cut time and helps lower cost per part. These advancements are evident in the machine’s casting, tank design and filtration system that help combat problems caused by EDM particles/residue generated by long hours of disk production cutting.
For faster, easier cleaning, the casting of the CUT 400 S Dedicated is designed so that tank water constantly runs down the interior sides of the work envelope, keeping them wet and preventing EDM residue from drying and hardening. This sticky residue also plays havoc with an EDM’s filter and drive systems. To prevent the residue from making its way inside these systems, water also constantly circulates through the new machine’s upper and lower heads.
