Aerofoils are some of the most critical aeroengine components. Their material capability and geometry directly affect engine performance and fuel consumption.
The aerospace industry’s constant drive to improve performance and efficiency places increasing demands on aerofoil manufacturing processes.
These improvements must be achieved through cost-efficient manufacturing processes which can meet production targets.
The AMRC with Boeing’s aerofoil platform team, part of the Machining Group, is dedicated to improving the performance and quality of aerofoil machining techniques.
The AMRC Factory of the Future offers a number of machining centres with proven capabilities in aerofoil machining processes. We can also draw on the additional capabilities of our key strategic partners.
Flexible five-axis mill-turn capability for single blade machining, from a range of inputs including forging and bar stock. Twin spindle and lower turret application allow the development of single-hit machining for complex aerofoil geometries.
Mori-Seiki NT4250 automated cell
Flexible five-axis mill-turn-grind capability for single blade machining from a range of inputs. The NT4250 has been integrated into an automated processing cell combining machining processes with mass finishing techniques (Rösler drag finishing and vibratory bowl) and rapid component inspection.
Starrag-Heckert STC1250 – Starrag-Heckert ZT1000
Large five-axis horizontal milling capability for wide chord fan blade (WCFB) machining as well as integrally bladed disc (blisk) and bladed ring (bling) applications.
Mori-Seiki NMV8000 – Hermle C50
Five-axis mill-turn capability (with additional grinding capability on the NMV8000) for blisk, bling and impeller applications.
Five-axis single blade and small blisk / impeller milling capability with the addition of through spindle coolant options including cryogenics (CO2 based), minimum quantity lubrication (MQL), air and conventional high-pressure coolant application.
We aim to cover all single and multi-bladed aerofoil applications for aeroengines and for power generation.
We can work with a variety of conditions of supply and machining processes to handle fan, compressor and turbine engine modules.
Our current research areas include:
- Advanced materials and condition of supply.
- Advanced component design and tighter tolerance features.
- Cost-based method of manufacture development.
- Process control, monitoring and modelling.
- Green button manufacturing methods.
- Milling, grinding and surface finishing processes.
Dr David Curtis – technical fellow
David joined the AMRC in 2009 after completing a MEng in Mechanical Engineering followed by a PhD entitled ‘Point Grinding and Electrolytic Point Grinding of Udimet 720’. During his time at the AMRC he has delivered a range of industrial and research projects encompassing advanced five-axis milling and grinding processes. He has technical responsibility for industrial project delivery and development of the aerofoil group’s strategic R&D roadmap.
Andrew Franks – project manager
Andrew joined the AMRC is 2010, after working in industry for 11 years with a leading automotive turbomachinary company, specialising in New Product Introduction and part approval. Since joining the AMRC, he has delivered a range of industrial projects to aerospace, automotive and marine partners. Andrew has project management responsibility for all industry-led and R&D projects within the aerofoils group.
Tom McCready – manufacturing engineer / NC programmer
Tom joined the AMRC in 2011 as a project engineer after completing a MEng in Mechanical Engineering and has since progressed to the position of manufacturing engineer within the group. He plays a leading role in technical project delivery and helps to support project engineer progression and supervision.
Andrew Winder – project engineer
Andrew joined the AMRC in 2012, after completing a MEng in Materials Science and Engineering and a Knowledge Transfer Partnership within the special metals industry. He works on industry-led
projects with a primary focus on R&D activity.
Joe Tindale – project engineer
Joe joined the AMRC in 2014, after completing a BEng in Mechanical Engineering. He works on industry-led projects and R&D.
– S-Quad (to follow)
– Aerofoil surface finishing (to follow)
Directed generic projects
– ITP blisk work (to follow)
– Coolant / tool holder benchmarking (to follow)
General case study
– Cell capability (to follow)