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A Case Study on 5-axis CNC Machining Scroll Stainless Steel Impeller
Release time:
Oct 09,2024
Project Background
Yixin Precision receives an order from an industrial equipment manufacturer to manufacture a batch of scroll stainless steel impellers for turbines. The impeller is made of SUS316. With excellent corrosion resistance and mechanical properties, SUS316 is suitable for harsh industrial environments. However, to process the impeller with complex geometry requires high precision and low surface roughness, which is a major challenge in machining.
Challenges
1. Material properties: SUS316 is susceptible to work hardening during machining, which largely results in tool wear. Thus, it has an impact on machining efficiency and quality.
2. Geometric complexity: the impeller has multiple curved surfaces and internal flow channel structure, conventional three-axis or four-axis equipment can not meet the needs of its complex shape machining.
3. High precision and surface quality requirements: The geometry of the blades must be highly consistent to ensure the dynamic balance and operational efficiency of the turbine. Meanwhile, the blades’ surface requires extremely low surface roughness to minimize air or fluid drag.
The Solutions
1. Equipment selection and process design
To process the scroll stainless steel impellers, Yixin Precision chooses the advanced 5-axis CNC machining center. By five-axis machining, multi-angle linkage processing of complex surfaces is available, and the number of clamping times is reduced. Therefore, the accuracy is ensured and the productivity is increased. For the complex runner area, a zoned machining strategy is used, and both rough machining and fine machining are combined well.
2. Optimization of tools and cutting parameters
In order to solve problems caused by the work-hardening characteristics of SUS316, Yixin Precision chooses coated carbide cutting tools and ceramic cutting tools when processing high-intensity cutting parts. The cutting parameters are optimized through experiments, and a lower feed rate and medium rotational speed is used to reduce tool wear and thermal deformation of the workpiece. At the same time, a highly efficient coolant system is used, which reduces the cutting temperature and prevents rapid tool wear.
3. Tool path optimization
Advanced CAM software is used to detailedly simulate the impeller geometry and plan the tool path, then idle running can be minimized and it avoids sudden tool cuts that lead to tool wear or workpiece deformation. Besides, the machining path adopts different feed methods in different areas of the tool to ensure the machining accuracy of each part.
4. Online measurement and quality control
During the machining process, an online measurement system is used. Through a precision probe, the thickness and curvature and critical dimensions of the blade in real time can be monitored. And it ensures the compensation is adjusted at any time during the machining process, which avoids machining overruns. The final impeller product is inspected by coordinate measuring machine (CMM) and dynamic balancing machine to ensure that the error of all key dimensions is controlled within ±3mm and the amount of unevenness is less than 0.1gmm.
5. Surface treatment
In order to meet the turbine's high requirements for impeller surface finish, the impeller was also ultra-precision polished after completion of machining, resulting in a surface roughness of Ra 0.3 or less, to ensure optimal hydrodynamic performance during high-speed operation.
| Product Name | Scroll Stainless Steel Impeller |  |
|||||
| Machining Equipment | 5-Axis CNC | ||||||
| Size | OD 110mm*55mm | ||||||
| No. of CNC Machining Tools | 4 | Total Time | 4h 30min | ||||
| Details No. |
Processes | Tool | Ap (mm) | Ae (mm) | Spindle Speed （rpm) |
Feed Rate (mm/min) |
Machining Time |
| 1 | Pre-machining | D10R1 | 0.35 | 7 | 2000 | 1000 | 0:50:50 |
| 2 | Angle-cleaning | D3 | 0.2 | 0.2 | 5000 | 400 | 0:25:10 |
| 3 | Fine-machining | D3R1.5 | 0.06 | 0.15 | 6000 | 1500 | 1:00:30 |
| 4 | Fine-machining | D3R1.5 | 0.03 | 0.1 | 8000 | 1000 | 1:45:40 |
Parts Highlight： 1.Incoming material is turning blank workpiece, with the thinnest blade thickness 0.9mm (height 28mm), five-axis stable machining. 2.High consistency in dimensional accuracy of the whole impeller, unbalance (gmm) within 0.07gmm. |
|||||||
| Inspection Item | Inspection Report | ||||||
| Impeller Balance Grade(gmm) | less than 0.07 | ||||||
| Inspection Equipment | Dynamic Balance Machine | ||||||
Results
Accuracy and consistency: The accuracy of key dimensions of all the impellers meets the design standard, with the thinnest blade thickness of 0.9mm (height of 28mm), and an unevenness of 0.1gmm or less, with an error control of ±3 micrometers or less, which ensures the balanced and efficient operation of the turbine.
Surface roughness: The surface roughness of the impeller reaches Ra 0.3, which significantly improves hydrodynamic efficiency and reduces energy loss during operation.
Machining efficiency: Thanks to the optimized tool selection and tool path, Yixin Precision has improved the machining efficiency by 20% and shortened the delivery cycle under the premise of quality assurance.
Customer Feedback: The customer is very satisfied with the high precision and smooth surface of the impeller, and has further established a long-term relationship with Yixin Precision for subsequent production of high-performance parts.
Summarize
This case fully demonstrates the advantages of 5-axis CNC machining technology in the machining of complex curved surfaces and demanding parts. Based on high-precision equipment, optimized process flow and strict quality control, Yixin Precision successfully solves the difficulties in machining stainless steel materials and provided customers with high-quality turbine impeller products.
Impeller, 5-axis CNC Machining,Yixin Precision,Impeller CNC machining
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