KYOCERA UNIMERCO

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Turbine blade machining Intelligent tooling solutions – cutting your costs

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Your innovative partner We aim at improving the competitiveness of our customers by reducing the unit costs in the cutting processes. Kyocera Unimerco does not just deliver tools. our tooling technicians have in-depth knowledge of power generation applications and each problem is analysed thoroughly to come up with the best possible solution for you. in cooperation with you, we design the ideal solution for your specific application. The tools are manufactured on advanced machinery in our four manufacturing locations. after delivery, we assist you, if necessary, with the implementation of the tooling solution to make sure that everything runs smoothly and you benefit from the optimum tool performance. Faster machining a result of our extensive research and development activities is high performance tooling solutions for turbine blade manufacturing reducing machining time considerably. instead of using HSS tools in a traditional process you can use a high performance tooling solution to achieve narrow tolerances much faster. Fewer tools needed in most cases, using this approach, the actual number of tools needed for manufacturing a turbine blade can be reduced. in some cases, the number of tools has been reduced by 30%. of course your advantages are lower tooling costs, shorter cycle time and thereby higher productivity. Surface finish With the optimised tooling package, you will achieve excellent surface finish results. Longer tool life The use of high performance coated carbide tools results in longer tool life. your benefits are less machine down time, as there are fewer tool changes, and a reduction in the number of internal measurements needed. We look forward to your inquiry for a customised tooling solution for your turbine blade application. 2 Kyocera Unimerco Tooling Ltd. Tel. +44 (0)1543 267 777

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Tooling solutions for turbine blade machining root form Brazed and solid carbide tooling solutions for rough and finish machining. cutter root form profile measuring reports are available. aIrfoIl to Platform transItIon Ball nose and taper ballnose tooling solutions. available for high speed machining and conventional 3-5 axis machining. Platform & shroud custom designed parallel and conical tools for maximum performance when machining at up to 400m/min. aIrfoIl Ball nose, lollipop, torus and barrel form tools are designed to maximise step over and consequently maximise surface generation rates. www.kyocera-unimerco.co.uk 3

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New technologies to ensure optimum machining efficiency › Power edge™ › new nano composite coating › newly developed geometry › new and improved carbide grade Give you. › Superior tool life › Great component quality › Highest possible feed rate › minimised cost per cut Market-leading delivery time 4 Kyocera Unimerco Tooling a/S Ltd. Tel. +45 +44 97 (0)1543 14 14267 11 777

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Root form Carbide-tipped profile tool on steel body › Very accurate profile meets narrow tolerance demands › Superior performance due to optimised geometry › c5 coating for optimum tool life › no presetting time - considerable time savings in tool room › Tool diametres up to 180 mm › market-leading delivery time Feed length Tool life cutting speed Vc Feed/tooth Fz machining time Surface finish original process HSS Profile tool, 25 480 mm 15 m 45 m/min 0.0016 mm/tooth 4,300 sec ra 1,1 our solution Sc-tipped tool, 25 480 mm 35 m 90 m/min 0.120 mm/tooth <200 sec » 10 times shorter machining time ra 0,5 SIMPLY JUST PLUG AND PLAY Carbide fir tree end mill Saving machining time: carbide tools for fir tree slot machining Previous solution HSS fir tree cutter Surface finish ra = 1.2 20 slots 710 sec. 2,000 our solution Sc fir tree cutter ra = 0,4 192 slots 335 HOURS SAVED PER MAC HINE Tool life machining time/slot Total numers of slots per year on this machine annual time saving or capacity increase 110 sec. 2,000 335 hours per machine HSS fir tree cutter (competitor’s solution) Sc fir tree cutter (our solution) Market-leading delivery time *Kyocera Unimerco customises each tool to meet the customer’s individual demand. The delivery time for a solid carbide fir tree cutter is 3 weeks from appoval of overall design. www.kyocera-unimerco.co.uk 5

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Intelligent tooling solutions airfoil – Solid carbide torus end mill We adapt the tool to the specific wishes of our customers, whether the main criteria is tool performance or tool life. Solid carbide tools are continuously updated to meet the increased market demands and to make sure that you get a solution which ensures the most competitive manufacturing process. Example of tool life optimisation annual tool cost savings Previous solution Z3 carbide Vc Fz machining time Tool life 400 m/min 0,08 mm/cutting edge 120 sec. 7 parts our solution Z6 nTS carbide torus cutter 200 m/min 0,08 mm/cutting edge 120 sec. 20 parts This customer achieved a saving of » 60,000 eUr in tool cost for this blade type alone Saving of > 60,000 EUR airfoil to platform transition – Taper ball nose carbide end mill typical case Previous solution Uncoated carbide tapered ballnose end mill our solution Unimerco Power edgeTm tapered ballnose end mill C7 PLUS Power Edge For this finishing operation we did not optimise on machining data, but our customer went from 20 blades tool life to 89 blades with our tool. C7 PLUS TECHNOLOGY Power Edge This meant for our customer › app. 20,000 eUr saved on this tool type alone › Significant time savings in tool room for setting up › Fewer regrind shipments › Lower tool cost per blade i.e. cheaper blade C7 > 4 times longer PLUS tool life Power Edge C7PLUS™ Power Edge titanium platform –Standard NTS end mill Performance example milling of titanium component (Ti-6ai-4V) roughing titanium platform ap = 7 mm ae = 12 mm Vc = 44 m/mm Fz 0,06 mm/tooth Previous carbide solution = 53 min tool life C7 PLUS COATING Power Edge C7 PLUS Power Edge nTS c7 PLUSTm Power edgeTm = 167 min tool life P o w e r Edge > 200 % increase in tool life 200 % increase in tool life 6 Kyocera Unimerco Tooling Ltd. Tel. +44 (0)1543 267 777

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Total quality – your guarantee for continuous performance specification system and service concept -10 Measuring report We know that producing turbine blades requires very narrow tolerances. in order to give you the best possible tool quality, we offer to measure each individual tool and document the findings in a measuring report. This is our way of documenting that the tools are manufactured according to your requirements, and that they are instantly ready to use - simply plug & play. RE•NEW® concept all tools are reground and re-coated utilising the same advanced technology as for the manufacture of the tools. and we regrind your tools with the same care that we use to manufacture new tools. We also RE•NEW® other tool brands with very good results. you will benefit from tool performances on reground tools, which can match or even surpass the performance of a new tool. 0 10 20 30 40 50 60 90 70 70 60 50 40 30 90 10 max. distan ce ins ide ma tan x. dis ce out Tolera nce error Tolera nce Date Filter (horiso ntal) correc atic r) Autom /mirro (rotate tion 80 aus / au s 80 20 File data 11 Measu red by BHS 4107 Profile 08-00 2264 _5_1 .cfd ! Manue l cor rection --al) -17,8 side µm data keine of poi nts Daten Manue l cor rection (vertik --Ord ) er 1036 15 14,5 µm --- er Numb 1558 ide / 6 e inside Smalle st tole ins rance outsid Manue l cor rection (rotate --- -7,5 µm / 7,5 µm :1 tion correc al) atic rtik Autom ntal/ve (horiso ein ein / error outsid e --- Error magni fication 100 8. ap ril 20 08 Packaging solutions To avoid problems during transport, all tools for turbine blade production are delivered in secure plastic or wooden boxes. For tools with larger diameters, a measuring report as well as a scan of the tool profile will be included in the tool box in order to avoid tools being mixed up. 100% repeatability Due to a unique internally developed norm system and a very advanced drawing database, we are able to continuously deliver tools with the exact same geometries throughout all future deliveries, regardless in which Kyocera Unimerco manufacturing facility your tools are being produced. www.kyocera-unimerco.co.uk 7

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KYOCERA UNIMERCO Tooling Ltd. KYOCERA UNIMERCO manufactures, distributes and services tools for machining, primarily for the metal, woodworking, automotive, aerospace, power generation and fluid power industries. The technology centre in Lich eld focuses on e ective solutions for production. The tooling concept comprises standard and customised tools, RE•NEW® tool maintenance, coating and optimisation guidance. The She eld branch specialises in supplying inserts, standard tools and related tool solutions to the industrial market in the UK, including the general machining, aerospace, o shore and medical industries. The company was established in 1998, services all of the UK, and is part of the KYOCERA UNIMERCO group, founded in Denmark in 1964 and originally named UNIMERCO. In 2011, all activities were acquired by Japan-based KYOCERA. This has created an even stronger company with a larger range of products, a wide network of companies and distributors all over the world, and an ambitious growth plan. Nanscawen Road, Fradley · Staffordshire WS13 8LH / UK Tel +44 (0)1543 267 777 Fax +44 (0)1543 267 778 umuk@unimerco.com www.kyocera-unimerco.com © Kyocera Unimerco 09.11 063_0005