When precision counts in electrochemical machining, the tool cathode plays a significant role: Its shape determines the removal of material at the workpiece. Therefore, its design and precise production is a particularly important machining task in the micrometer range. For its development, EMAG ECM therefore has a large development area with a largely digital workflow.
The blisk tool in three steps
Currently, the specialists based in Gaildorf, Germany, are undertaking an important step in this context: The calculation of cathode shapes for blisk, disk, diffuser, etc. will be performed with the “EMAG Tool Designer” software, an in-house development. Toolmaking will involve the following three steps: Step one is a precalculation (IT0) of the cathode with the “EMAG Tool Designer”, based on the 3D geometry data of the component. After the cathode is completed, a first machining process starts in the PECM machine. Next comes an optical 3D measurement at the finished component. The measurement results are fed back into the “Tool Designer”. The program calculates the necessary corrections at the cathode.
Precision for turbine production
The corrected tool is then tested again, or the finished component is measured. If the values are correct, the development process is completed. At the end, the specialists will always provide their customers with a high-precision tool – a basic prerequisite for accurate production during the PECM process in turbine production.