In the project ADMAP-GAS new Unconventional Advanced Manufacturing Processes for Gas-Engine Turbine Components developed in order to substitute the critical conventional broaching process for fir tree profiles between rotating blades and disks. Therefore the two manufacturing technolgies “High Speed Wire-EDM Broaching” and “Abrasive Water Jet Broaching” – W² - developed, optimised and evaluated highlighting their individual performance and effectiveness for the machining task. High material removal rates and highest surface finishing achieved resulting in an equal or even better workpiece performance. By using these two unconventional manufacturing technologies with their inherent advantages a much higher technological and time based flexibility in production of fir tree profiles achieved. Failure risks and machining costs drastically decreased due to faster and more efficient machining in combination with a higher degree of automation.
Tool wear and time consuming tool renewal avoided. Machine tool footprints (in comparison to conventional horizontal broaching centers) or machine heights and fundamentals (vertical centers) drastically reduced. Energy consumption reduced and environment preserved. ADMAP-GAS addresses the relevance to the call by the “development of techniques for increased flexible tooling” for the manufacture of gas turbine components. The W² technologies also enable the application of innovative and light weight design concepts (more complex shapes, tighter tolerances, etc.) for the turbine components that were not possible due to the technical limitations of the broaching process. This additionally resulted in reduced production costs across the whole production cycles. Production waste and consumables minimised. A high degree of automation and faster machining times resulted in a highly effective machining process with virtually no failure risk.