Geripptes Aluminium-Rotorgehäuse — 38 Rippen, 0,9 mm Wandstärke
Ein geripptes Rotorgehäuse mit 38 gedrehten Rippen und sechs Innenstegen, aus 6061-T6 Vollmaterial gefertigt, mit 0,9 mm Rippenstärke auf ±0,05 mm über den gesamten Durchmesser von 160 mm.
Bauteildaten
- Branche
- Industrial Machinery
- Verfahren
- CNC Turning + Milling
- Werkstoff
- Aluminium 6061-T6
- Toleranz
- ±0.05 mm
- Oberfläche
- Bead blasted, clear anodised
- Stückzahl
- 250 / release
- Lieferzeit
- 14 working days
Kundendaten aufgrund eines NDA nicht genannt.
Herausforderung
The customer's previous supplier could not hold fin thickness consistently: fins near the outer diameter came out 0.15 mm thicker than those near the hub, and roughly one part in five showed chatter marks that failed the cosmetic specification. Thermal performance depends on fin pitch, so the variation was a functional problem, not just an appearance one.
Lösung
We reversed the process order — turning the fin profile first while the billet was still rigid, then milling the internal rib pocket from the back with the part supported on a purpose-built vacuum fixture. Fins were cut with a ground form tool at constant surface speed and a light final pass, and the job was stress-relieved between roughing and finishing to stop the hub pulling as material came out.
Ergebnis
Fin thickness now holds ±0.05 mm from hub to rim, chatter has been eliminated, and the scrap rate dropped from 19 % to under 1 %. Cycle time fell 22 % against the original process despite adding the stress-relief step. The part has been in repeat production for eleven releases.
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