The high-precision turbocharger impeller is the most stringent key component. Through advanced 5-axis machining, hundreds of turbocharger impellers can be manufactured every day. Using solid aluminum milling, compared with the old-fashioned cast supercharger, not only has the price advantage but also higher tolerance accuracy.

The turbocharger is a 100% 5-axis machining workpiece, without any straight cut or pure arc machining. The shape of the wheel is roughly conical, with a large number of airfoil blades radiating spirally from the hub and along the axis of the cone. At each processing moment during the processing of the speed increaser, the milling path changes along all the processing axes, so each axis is always in the acceleration or deceleration mode, which will cause severe gravity acceleration during processing.

The turbocharger impeller processing of a certain manufacturing plant is completed by four FSP model 300x high-speed five-axis machining centers, which are products of MooreToolCo of Bridgeport, Conn. The most striking thing about this machine is that the fixed-position horizontal spindle can only move along the X and Y axes. Only restrict the movement of the main shaft in the horizontal direction, and does not change the extension of the main shaft. This can increase the rigidity and increase the vibration damping when the inertial force is large, which is very common in the processing of the supercharger.

The rotating design of the workpiece table (upper table) avoids the offset of the center of gravity of the hinge axis during complex contour cutting, and improves the response and accuracy of the cutting path. A horizontal spindle can be removed faster chips, without double milling.

The large, cast iron and three-point horizontal box-in-box structure enhances stability and vibration absorption. The processing contour feed rate can reach 787ipm, the speed can reach 1,181ipm, and the acceleration can reach 653in./sec2 or 1.7G in the five-axis mode.

FSP300s also incorporates a high-gain, closed-loop digital servo system that can quickly position, high feed rate and acceleration on all axes. Moore can obtain this advantage because it captures the essence of machine tool design and minimizes the effects of harmonic effects, vibration and shock by coordinating machine tools and control systems. And make the Siemens Sinumerik840D control system of the machine tool at a normal working level. Rob Smith, manager of Moore, said, “When a low-rigidity machine tool is running at Taps speed, with such a high gain, the control system must become dynamically unstable.”

Turbocam Parts: When processing impellers from solid aluminum, use MooreFSP300xHMCs to remove more than 50% of the weight in the Taps automated production system. And finish the impeller processing in about 1 hour while keeping the volume error within 0.001 inches.

He said that the Siemens control system can provide high processing and processing speed and true five-axis machining. And there is no need to stop any axis during processing. Stopping the axis will greatly reduce the processing speed in complex contour processing.

The 840D control system can control 10 channels, 10 pattern groups, and 31 axes. In order to meet the high demand for axes and channels, the computing power and storage area of the NCU can be expanded and combined. This allows 840D to connect 248 axes and spindles on a CNC.

A 4-inch supercharger cut from 2618 aluminum. Using the reciprocating feed device designed by Moore, the machine tool can run unattended. Cut off 50% of the weight and complete the processing of the booster within 1 hour, and the volume error can reach 0.001 inches.

The quality of the machine tool was verified by machining a 10-inch turbocharger. The machining required 7 contour cuts and 7 tool changes from the beginning of the entity.

FSP300 finished the processing within three hours and all the surfaces met the size and finish requirements. For this cutting, the feed rate is in the range of 190 to 282 sfpm, while the spindle speed is in the range of 24,000 to 40,000 rpm.

1005TAPSactivearea: The table-on-table rotating design of the MooreFSP300xHMCs workpiece table avoids the center of gravity shift of the hinge axis during the complex contour cutting process of Taps, and improves the response and accuracy of the cutting path.