Detecting the critical dimensions of large batches of complex workpieces is not only difficult and time consuming, especially when all the produced workpieces must be inspected.
Europea Microfusioni Aerospaziali, a turbine blade manufacturer headquartered in Morra De Sanctis, Avellino, Italy, now uses the Renishaw PH20 five-axis head to perform these tests. The inspection cycle is shorter than using a three-axis system. Up to 50%.
Vittorio Caggiano, Marco Iannuzzi and Maurizio Rullo in EMA's Measurement Room
background
Europea Microfusioni Aerospaziali (EMA) is one of the subsidiaries of the Rolls-Royce Group. The Group is a leading manufacturer of propulsion systems worldwide, mainly for civilian and military aircraft, ships, submarines and turbine manufacturing (for the production of industrial energy). system.
EMA's measurement room
EMA's production facility in Morra De Sanctis includes a 20,000-square-meter facility that specializes in producing ultra-high-precision specialty alloy stator and rotor blades for civilian and military high, medium, and low-pressure aviation turbines. The company also produces industrial turbines for power generation. Production of blades.
EMA's Multi-blade Parts AEREO
More than two-thirds of EMA's products are supplied to well-known customers in the aviation industry in Italy and around the world, including the parent companies Rolls-Royce, AgustaWestland, Ansaldo Energia, Avio, Turbocare, Siemens, MAN and Snecma. About 25% of the world's military aircraft With the Rolls-Royce engine installed, many of these engines use EMA products.
'Since the introduction of the Renishaw PH20 head, we have significantly reduced the measurement time and the number of stylus exchanges performed during the test cycle. Using the MODUSTM software also reduces and optimizes the programming time. We have managed to reduce the test period by 30-50%. , in some cases even more than 50%.'
Europea Microfusioni Aerospaziali (Italy)
challenge
Turbine and aero engine blades are made of superalloys that can withstand extremely high temperatures and pressures. Their shapes are generally more complex to maximize efficiency and reduce stress and fatigue. However, these blades are manufactured using the most traditional of humans. One of the techniques - produced by casting technology.
EMA completes a variety of micro-casting technologies, including the technology used to produce single-crystal blades of metal alloys. The company also specializes in lost-wax micro-casting processes that first create wax patterns obtained from metal molds.
These wax molds are then coated with a high-temperature resistant ceramic material. Then the wax is removed to form the ceramic shells for the superalloy molds. After the castings are solidified and cooled, they are heat treated and polished, and passed through ultrasonic waves, X-rays. And liquid penetration testing to check the dimensional accuracy and structural integrity of all parts.
Due to the complex geometry of the workpiece and 100% inspection requirements, it is challenging to design an efficient process to check the dimensional accuracy of turbine and aero engine blades.
solution
Vittorio Caggiano, Quality Control Manager, said, 'We must find a solution to increase the efficiency of the dimensional inspection process by measuring the number of parts per unit of time.'
For this reason, EMA can choose to purchase new measuring equipment or shorten the measurement time, thereby improving the company's existing measurement equipment measurement capabilities.
'Until a few years ago, our coordinate measuring machine was equipped with the PH10 three-axis repositionable head, but there are some restrictions on the movement and stylus exchange time.' Caggiano said. These limitations are due to the complexity of the workpiece caused , Each measurement cycle requires several stylus exchanges.
'We worked closely with Renishaw's technicians to find better solutions. We also sent artifacts to Renishaw's agency in Turin for testing. After testing, we believe that the best solution is to purchase more flexible Efficient new PH20 5-axis measuring head, and MODUS measuring software. Renishaw retrofits the new touch probe to our existing CMM, and Renishaw SpA employees prepared 50 measurements during our training session. Procedures. '
result
'The end result was very satisfying,' added Maurizio Rullo, a coordinate measuring machine programmer. 'Since the introduction of the Renishaw PH20 head, we have significantly reduced the measurement time and the number of stylus exchanges performed during the test cycle. Reduced and optimized programming time. We have managed to reduce the inspection cycle by 30-50%, and in some cases even over 50%!'
Maurizio Rullo is using Equator
EMA also purchased the Renishaw EquatorTM, which allows quick and efficient measurement of the geometry and shape of large batches of workpieces.
Thanks to Renishaw's Equator, we are able to focus all necessary measurements on certain components; in the past, multiple measuring instruments were used to complete these tests. As a result, the inspection time for high-volume workpieces has been significantly reduced. Mr. Rullo concluded.
Renishaw PH20 and MODUS Software
The PH20's unique 'head touch' allows measurement points to be collected only by moving the head instead of the coordinate measuring machine. Using the swivel motion of the head, you can acquire measurement points faster and get higher Accuracy and repeatability. In addition, five-axis linkage eliminates the need for swivel positioning.
The stepless positioning function of the PH20 ensures the best feature measurement and minimizes stylus exchange. Five-axis simultaneous movement reduces the space required for the swivel positioning of the head around the workpiece, allowing larger workpieces to be measured on the CMM The PH20 is automatically aligned with the workpiece coordinate system to avoid stylus collisions and requires no precision fixtures.
The unique 'inference calibration' technology developed for the PH20 allows the head orientation and head position to be determined at a time, enabling subsequent measurements at any head angle.
PH20 is testing EMA's multi-leaf parts AEREO
The PH20 can be automatically aligned with the workpiece coordinate system: There is no risk of collisions and complicated fixtures are eliminated.
The unique rapid calibration system function can determine the direction of the probe and probe at one time, enabling measurement at any angle.
The MODUS measurement software simplifies the complex measurement applications and shortens the measurement cycle. The software has a probe path simulation, collision detection and screen detection functions that support off-line programming in CAD. The above features of MODUS help to reduce machine downtime; The written program can be loaded on the machine for use at any time, requiring little or no testing at all.
Original article published by Ernesto Imperio on Tecnologie Meccaniche
For more information, visit www.renishaw.com.cn/ema