• Articulated cage—produced on an EMAG vertical turning center VTC 100-4
    Articulated cage
  • PECM for the machining of blisks
    Blisk
  • Brake disc
  • Cam
  • Composite camshaft for a small engine
    Composite camshaft (joining)
  • Automobile crankshaft machined on the PM 2 series.
    Crankshaft (automobile)
  • Crankshaft (for small engines)
  • CV joints make high demands on the machining technology. Core components: Kingpins, articulated cage, joint ball
    CV Joints
  • Dies
  • Differential pinion—precision machining on VL machines
    Differential pinion
  • Differential housing
  • Distributor flange
  • Feed screw
  • Flange manufactured on VL 2 lathes
    Flange
  • Gears are machined on EMAG VL series machines
    Gear
  • Gear shaft
  • Composite gear shaft manufactured with high precision by the use of EMAG heat shrink assembly technology.
    Gear shaft (joining)
  • Gear shaft (laser welding)
  • Gear with synchronising wheel
  • Gear of an automobile gearbox manufactured on a VLC 200 H
    Hobbing gears
  • Injector body
  • Machines by the EMAG Group for Kingpin production
    Kingpins
  • Master brake cylinder
  • To machine pistons with precision poses a particular challenge for all manufacturing solutions
    Piston
  • Pump ring production on the high-precision SK 204 grinder
    Pump ring
  • Railway wheel manufactured with precision on VLC 1200 turning centers
    Railway wheel
  • Roll rings are precision components
    Roll ring
  • Screw
  • Sprocket
  • Sprocket (Manufacturing System)
  • Steering pinions can be machined with great precision on the EMAG VT machine
    Steering pinions
  • Triple-sector clutch
  • Surface layer hardening an armature shaft on an eldec MIND 750
    Armature shaft
  • Input shaft
  • Balance shaft
  • Induction hardening through precision control
    Hydraulic Valve
  • Camshaft
  • Hardening shifter shafts with induction hardening
    Shifter Shaft
  • Surface layer hardening with the eldec hardening machine
    Wheel Hub
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Blisk

PECM for the machining of blisks

Components inside an aircraft engine are exposed to extreme stresses, and therefore made from very hard materials. For example a Blisk (Blade Integrated Disk) is often made from nickel-based super alloys. Conventional cutting methods become uneconomical as the material hardness increases and the service life of expensive tools drops, therefore causing costs-per-piece to rise. PECM and machines by EMAG offer an elegant solution for this problem.

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Blisk machining with Precision electro-chemical machining, gentle material removal – fast processes

The PECM technology supplied by EMAG ECM based in Gaildorf Germany removes material without contact and causes minimal tool wear while being fast and reliable. During the process, the workpiece becomes the positive anode and the tool the negative cathode. An electrolyte solution flows between them, removing metal ions from the workpiece. The form of the cathode (tool), with its active, conductive zones results in material removal from the workpiece at the required component contours. Ring ducts, grooves, bell hollows and other contours can be produced without contact, but with very high precision and excellent surface quality.

Machines for the machining of BLISKS and single blades: EMAG ECM has two machine types for the different machining tasks of jet engine production: while the small model PO 100 SF is designed for machining single turbine blades, the larger PO 900 BF is for machining the complete, and therefore much larger, blisk. Both these machines also provide the user with central EMAG innovations such as a Mineralit® polymer concrete machine base, intelligent software and hardware interfaces and efficient automation solutions.

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