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Machining the turbine blade

Super alloys and titanium for maximum loads

Turbine blades are subjected to phenomenal thermal stresses and must always deliver peak performance over the entire life of the aero engine. Super or titanium alloys and a steady stream of newly developed materials make them particularly resilient. However, these materials are extremely difficult to machine.

CERATIZIT tool systems, which are designed to deliver maximum levels of productivity, keep machining times within acceptable limits, even during the complex roughing processes used for the rhombus and blade.

1. MaxiMill HFC-TUR

High-feed indexable insert milling system for larger cutting depths

  • HFC milling with larger cutting depths than conventional systems owing to the adapted setting angle
  • Coated carbide grade CTCS245 for heat-resistant alloys and CTC5240 as the benchmark in titanium machining

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2. MultiLock for solid carbide milling heads

Highly efficient finishing due to the patented exchangeable head system

  • Cost-effective, unbeatable price-performance ratio
  • Closes the gap between indexable insert and solid carbide systems
  • Extensive product range for other applications

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3. MaxiMill 251

Versatile machining options with button inserts

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4. MaxiMill 261 – ceramic

Extremely productive freeform milling with positive button inserts, machining of large areas of Ni-based alloys

  • Extremely productive: more than 10x higher cutting speeds possible compared to carbide inserts
  • Drastically shortened machining times for roughing, regardless of the machining strategy

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5. Solid carbide conical ballnose milling cutter

Machining of transitions on blade root and blade tip

  • Adapted geometry for the machining of special contours on Ni-based alloys and titanium

Practical examples of the tools

MaxiMill HFC-TUR

Turbine blade

  • Material: 1.4418, Cr17Ni4Cu4Nb,
  • CT tool: AHFC.50.R.05-12-TUR
  • CT indexable insert: XOLX 120410ER-F40 CTC5240
  • Application: freeform roughing
Cutting data CERATIZIT Competitor
Vc [m/min] 224 224
fz [mm/tooth] 0.55 0.3
ap [mm] 1.15 1.15
Emulsion Yes Yes
Q [cm3/min] 142 78
Tool life [min] 1 0.5

MultiLock for solid carbide milling heads

  • Material: Ti6Al4V
  • Tool: special exchangeable head
  • Application: 3D finish machining of an airfoil
Cutting data CERATIZIT
Vc [m/min] 120
fz [mm/tooth] 0.045
ap [mm] 1
ae [mm] <9
Emulsion Yes
Tool life [min] 320

MaxiMill 261 – ceramic

Turbine blade

  • Material: Nimonic 80A
  • Tool: G261.32.R.03-1204
  • Indexable insert: RPGN 120400EN CTIS710
  • Application: heliroughing of a turbine blade
Cutting data CERATIZIT Competitor
Vc [m/min] 1000 1000
fz [mm/tooth] 0.1 0.1
Vf [mm/min] 2984 2984
ap [mm] 3 3
ae [mm] Variable Variable
Emulsion Dry Dry
Tool life [min] 8 5.5
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