Deburring inside air foil cooling blades cropped

Deburring inside air foil cooling blades during the post laser clad machining process.

"A significant improvement in the workpiece surface finish as well as a longer-lasting bur."

 

A leading industrial gas turbine MRO service provider in South East Asia contacted ATA for help in recommending an alternative bur solution to improve productivity and reduce their consumption of burs. 

There is a high cost associated with the repair of the turbine blades so improvements to the process to lessen this cost was imperative for the company to remain competitive.

The specific application involved the repair of large nickel alloy turbine blades and the removal of weld from the component which required heavy stock removal but needed to have a fine surface finish.

The specific application involved the repair of and removal of weld on large nickel alloy turbine blades, which required heavy stock removal but needed to have a fine surface finish.

The company had been using a range of Single Cut burs provided from their region for many years but were experiencing very fast wear on the burs and a lot of clogging in the teeth. This meant that the finishing time on the components was slow and operators were experiencing a lot of downtime from changing burs.

ATA worked closely with the company, trialing a number of bur cuts to ensure the optimum solution was found.

Following conclusive results, ATA recommended a combination of our aggressive ATA Cut 5 (Foundry Cut) bur which is designed for heavy deburring to remove non-ferrous metals, along with our high-quality ATA Single Cut (Cut 2) bur to achieve a fine finish.

Cleaning large blades

Using the Cut 5 to remove material and clean a large turbine blade.

bur comparison_Case study

Photos showing the chipping and wear that the customer experienced with the competitors Cut 2 bur, compared to the undamaged ATA Cut 2 after testing.

When implemented into their operating process, the customer reported that the ATA Cut 5 removed the material much faster and improved their overall speed, quality, and productivity thanks to the efficiency delivered by the aggressive geometry design and reduced clogging of the teeth.

By replacing their problematic Cut 2 bur with the higher quality ATA Cut 2, the customer reported a significant improvement in the workpiece surface finish as well as a longer-lasting bur which had the additional benefit of reducing the overall quantity of burs used.


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Bespoke Solutions

Every year, hundreds of customers globally benefit from ATA’s bespoke engineered solutions to enhance performance and process across a spectrum of material stock removal applications.

If you would like to speak to us about a challenge you are facing, or find out how our products could help improve your manufacturing processes, contact us today. 

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Cutting Tool Solutions

You can now buy the Karnasch Professional Tools range through your existing ATA supply channel and enjoy the same high standard of customer and technical support.

Karnasch offer excellent performance and consistently high quality products for milling, drilling, reaming, countersinking, grinding and sawing of almost all materials.