Automated blisk production

At the heart of the manufacturing process is the 96-meter long main distribution system. Controlled by a central computer, this system assigns an order number – stored on a chip – to every new component. By calculating the up-to-date availability of the fixtures and tools, the computer can calculate the workloads of all of the shop’s workstations. The distribution system then conveys the components to the respective machines.

The 24 Mikron HPM 800U milling machines used to manufacture blisk blades play an essential role in the overall efficiency of the manufacturing facility. Instead of having to provide a specially adapted machine for each specific machining task, this solution enables MTU to manufacture all blisks required for the GTF programs in a single, integrated manufacturing cell.

Right down to components as small as screws, the 24 Mikron HPM 800U milling machines are absolutely identical. The reason for this uncompromising approach is clear: only machines that are built to exactly the same specifications will deliver exactly the same results – and that’s a key requirement for blisk production.

This machining cell consists of seven Monforts UniCen 1002 machines used for the turning and milling of blisk components. This type of machine is especial­ly well suited to the processing of hard, difficult-to-machine materials such as those typically employed in the manufacture of turbine components. In the 5-axis control configuration, the tools can be brought into almost any position and angle relative to the workpiece. Parts are loaded to and unloaded from the turning and milling center via an area gantry system.

In the set-up area, the components to be machined are mounted onto rigs. The CNC controller then routes the rigs via a shuttle system to the various stations of the blisk production facility. The components themselves are retrieved from a rack storage system that extends along the entire rear wall of the facility.

This cell is responsible for configuring the tools as needed for the various steps of the mill­ing process using different machines. Even the slightest error at this point could have serious consequences on the entire production chain.

Deburring is a manual operation in which sharp edges and rough areas of machined components are removed. One of the tasks performed here is slide grinding, to prepare the blisk blades for subsequent polishing.

Although the machines on the shop floor are tremendously accurate and reliable, there can be no compromise on quality when it comes to safety-critical components. That’s why the final inspection of the blisks is carried out by experienced production workers – because no amount of technology can replace the trained eye of an expert.