CAD/CAM solutions for efficient machining of turbo machinery components by Sturz milling method

Rapid developments in the fields of engineering and their applications in manufacturing processes have brought real changes in product designs, evolving more efficient and complex designs. Application of ball end machining for generating complex sculptured surfaces tends to be nonproductive especially in places where large sculptured surfaces and/or large volume of production are involved. Kaplan blades are one of the vital components in hydro turbines which have large sculptured surfaces and involve bulk metal removal while machining from forged blanks. Conventional ball end machining methods are not adequate to achieve the required productivity and quality while manufacturing these components. With the advent of multi-axes CNC machines and powerful CAD/CAM solutions-“Sturz milling”, an innovative method of sculptured surface machining has become not only feasible but also cost-effective for the production of these components. This paper discusses the Sturz milling method, control parameters, it´s performance in comparison with conventional ball end milling and also the customisation of the CAD/CAM CNC programming solutions to evolve efficient machining patterns