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The pursuit of high-quality, efficient, and low-cost manufacturing methods has become a global priority in aerospace engineering, especially when dealing with difficult-to-machine materials and complex structures. Choosing the right processing technique is crucial to achieving design objectives. EMAG Electrochemical Company from Germany has introduced a multi-axis CNC precision electrolytic machining technology that completely replaces traditional high-speed milling and five-axis EDM processes for manufacturing whole leaf discs. This non-traditional cutting method offers significant advantages.
In response to the growing demand in the aviation industry, Airbus projected in 2012 that between 2012 and 2031, the global market would require 28,200 new aircraft, valued at nearly $4 trillion. To capture this massive market, manufacturers must invest heavily in innovative technologies. Modern civil aircraft are increasingly focused on environmental sustainability, economic efficiency, and improved performance metrics such as aerodynamic and structural efficiency. These factors drive the development of advanced aero-engines, which aim to increase thrust-to-weight ratios, extend service life, and reduce energy consumption.
Integral leaf discs are a key component in modern aero-engine designs. They integrate blades and discs, eliminating traditional joints and reducing weight, parts count, and airflow losses. This design improves engine efficiency and reliability. The use of advanced materials like composites, titanium alloys, and nickel-based superalloys further complicates the manufacturing process. As a result, there's a strong need for high-quality, efficient, and cost-effective machining solutions.
Multi-axis CNC precision electrolytic machining (PECM) stands out for its high efficiency, no tool wear, and minimal residual stress. Unlike conventional milling, it allows for precise shaping of thin, complex structures without deformation. EMAG’s patented technology has led to the development of seven-axis CNC high-frequency narrow-pulse electrolysis machines, which are among the most advanced in the world for aerospace applications.
This process is particularly effective for high-temperature alloys, where traditional machining methods face challenges due to material hardness and tool wear. EMAG’s PECM technology not only improves productivity but also significantly reduces costs. With surface roughness as low as Ra ≤ 0.2μm and contour accuracy within 0.06mm, it meets the highest standards of precision required in aerospace manufacturing.
EMAG offers a complete process chain, from initial blank processing to final blade shaping, providing a turnkey solution tailored to customer needs. Their PO 900 BF machine is designed for high-frequency, narrow-pulse electrolysis, ensuring consistent quality and efficiency. This technology enables mass production while maintaining high standards of accuracy and cost-effectiveness.
By adopting EMAG’s multi-axis linkage CNC precision electrolytic machining, aerospace manufacturers can overcome the challenges of producing complex, high-performance components. This innovation not only supports the development of next-generation aero-engines but also paves the way for more sustainable and efficient aviation systems.