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Test & measurement


Our accuracy in fine milling of bladed disks is more than four times better and the related labour costs have been halved.”


SPRinT Technology The OSP60 on-machine 3D scanning probe is equipped with Renishaw’s unique SPRINT technology. As the probe stylus tip precisely follows a


Renishaw and Technopark Aviation Technologies are working together to solve issues surrounding manufacturing and quality checking the curvature surfaces of bladed disks used in gas turbine engines


the milling of bladed disks included the following requirements:


Semi-finishing using a parameterised control program


On-machine workpiece inspection


Correction of the parameterised control program based on inspection results


Fine milling of the workpiece using the corrected parameterised control program.


SoluTion Technopark was selected to develop and implement the process controls needed. Semen Starovoytov, candidate of Technical Science and head of the Innovation Department at Technopark says. “We have worked successfully with Renishaw for many years, equipping machines with Renishaw touch-trigger probes to achieve flawless measurement accuracy.” “In the case of the application a clear


need arose for software development based on a scanning probe, so we approached our partners from Renishaw. Their SPRINT 3D scanning measurement technology for machine tools provided all the technical capabilities we required.”


ReSulT The introduction of Productivity+ and the OSP60 probe has had a significant impact on the bladed disk manufacturing process in terms of machining accuracy, speed and labour costs. The 3D scanning and measurement of bladed


disks on the machine tool and at very high speed has generated exceptional time savings in the production process resulting in a marked increase in CNC machine productivity.


Instrumentation Monthly January 2021 51 With respect to bladed disk milling accuracy,


a comparison of the respective deviations in bladed disk cross section and longitudinal cross section after edge machining showed a dramatic improvement, from 0.082 mm and 0.111 mm with the former process to 1 µm and 28 µm on the new. On the implications for machine manning,


Starovoytov says, “The control system’s execution mode ensures automatic adjustment of the CNC control program based on the 3D blade scanning data delivered by the OSP60 probe. This means there is no longer a need for an engineer to be at the machine constantly.” He concludes, “The combination of SPRINT


3D scanning technology and Productivity+ CNC software means that even the most minor deviations in bladed disk form are always identified in real time. With touch-trigger systems these would have gone unnoticed.” “The results we have gained from the


investment have far exceeded our expectations.


bladed disk surface, it allows high-resolution stylus deflection data to be recorded with exceptional accuracy, registering all sub-micron X, Y and Z movements at the ultra-responsive stylus tip. The OSP60 sends a thousand XYZ tip


centre data points to the OMM-S receiver every second using a high-speed noise- resistant optical transmission link. Advanced algorithms then process the probe deflection data together with machine tool position encoder data to produce accurate bladed disk surface data, which is used to calculate precise feature position, size and form.


PRoducTiviTy+ Technology Using the Productivity+ CNC plug-in, scanning speeds of up to 15,000 mm/min can be achieved, providing on-machine measurement sometimes six times faster than traditional touch-trigger systems. Bladed disks are scanned on the machine tool and the requirement to remove workpieces during processing is eliminated. The software displays high accuracy


measurement results on-screen in real-time and uses them to automatically adjust machine tool settings for the ensuing fine milling process. Measurement reports can be exported to file for analysis or quality assurance purposes. Bladed disk inspection programs can be


generated quickly and easily from solid model geometry using existing off-machine graphical programming tools, while the interactive front end of Productivity+ is used for editing and running probe inspection routines with easy-to- understand graphical screens, instead of complex NC codes to display the program to the user.


Renishaw www.renishaw.com/technopark


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