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Efficient machining of complex-shaped seal slots for turbomachinery
Authors:Umang Maradia  Mikhail Kliuev  Christoph Baumgart
Affiliation:1. GF Machining Solutions, Losone, Switzerland;2. Institute of Machine Tools and Manufacturing (IWF), ETH Zürich, Switzerland
Abstract:Complex sealing arrangement in turbomachinery can increase turbine efficiency by reducing leakage of high-pressure cooling flows into the hot gas path. While die-sinking EDM is widely used to machine straight seal slots, electrode preparation and wear make it less efficient for complex shapes. This paper presents research on optimisation of a variant of EDM milling using process control and fluid dynamics simulation to exploit optimal machining conditions. The analysis demonstrates a stable process to machine complex shaped slots by focusing on the key requirements for large-scale turbomachinery component manufacture, namely productivity, surface integrity and process monitoring.
Keywords:Electrical discharge machining (EDM)  Surface integrity  Seal slots
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