Process Development & CAM Programming for Complex Aerospace Components
Cost-Efficient 5-Axis Milling Processes for Impellers, Blisks, and Turbomachinery Components
Keller Aerotech supports companies in the aerospace and turbomachinery industries in the development of new 5-axis milling processes as well as the optimization of existing ones. CAM programming, tool selection, and workholding strategies are defined to ensure stable and cost-efficient processes under real shop-floor conditions.
Keller Aerotech – Your Partner for Stable and Cost-Effective Manufacturing Processes
Development of Robust 5-Axis Milling Processes for complex Part Geometries
Keller Aerotech develops machining processes for complex geometries with the objective of achieving stable and cost-efficient results in real production environments. Each milling process is specifically tailored to the customer’s manufacturing setup, including machine tool, cutting tools, workholding concept, automation, and coolant strategy.
Services
Process Development for Complex Machining Applications
Analysis and definition of machining processes using a holistic approach that considers all relevant parameters, including machine tool capabilities, cutting tools, and workholding, to ensure a comprehensive and robust process evaluation.
CAM Programming for 5-Axis Milling Operations
Development of efficient 5-axis milling strategies for roughing, rest material removal, and finishing, taking into account machine kinematics, collision avoidance, and tool life.
Optimization of Existing Manufacturing Processes
Evaluation of existing toolpaths and machining processes with the objective of reducing cycle times, minimizing risks, and increasing overall process reliability.
Postprocessors for Impeller and Blisk Applications
Keller Aerotech offers custom-developed postprocessors specifically designed for generating NC programs for complex 5-axis milling processes. The focus is on clean and stable NC code that accounts for machine kinematics and CNC control requirements, with a specific focus on machining impellers and blisks.
Advanced Software-Based Process Solutions
For machining tasks that cannot be fully addressed using standard functions of common CAM systems, custom software-based solutions are applied. This enables the development of specialized machining strategies and targeted process optimization.
Typical Components
Impellers and Rotors
Different blade geometries and materials require sophisticated milling process definition. The focus is on stable 5-axis milling processes for roughing and finishing operations to ensure repeatable results and controlled process conditions.
Blisks and IBR Components
Complex 5-axis simultaneous machining, often in difficult-to-machine materials, requires clean and continuous CAM strategies from the first to the last cut. Special attention is given to collision-free toolpaths, constant process conditions, and reliable implementation on the real machine tool.
Technical Environment and Methodology
CAD/CAM-Based Process Development
Process development and CAM programming are based on established CAD/CAM systems with the goal of creating robust and long-term maintainable manufacturing solutions. The focus is on clearly structured, traceable toolpaths and repeatable execution on the machine.
5-Axis Milling Machines, Kinematics, and Tooling
All machining strategies are designed taking into account actual machine kinematics, tooling concepts, as well as specific workholding and manufacturing conditions. The objective is reliable execution of CAM programs on the actual machine tool.
Aerospace Materials
Extensive experience in machining titanium alloys, nickel-based superalloys, and aluminum materials, with a focus on process stability, tool life, and consistent part quality.
Why Keller Aerotech?
Practical Process Development Focused on Implementation
Milling processes are developed to function reliably and repeatably under real production conditions. This is based on extensive practical experience in the development and implementation of 5-axis milling processes for demanding aerospace components.
Consideration of Actual Machine and Manufacturing Conditions
Machining processes are designed taking into account the actual machine tools, cutting tools, workholding, and operating concepts in order to ensure repeatable and reliable implementation on the shop floor.
Direct and Technically Sound Collaboration
Clear and focused technical coordination with engineering, process planning, and manufacturing as the foundation for efficient and reliable processes.
Support for Your Machining Project
Project Inquiry and Initial Consultation
Are you planning a demanding 5-axis milling project or looking to further develop existing processes? We would be happy to discuss your project and the potential next steps.