Wire Erosion Project – Aerospace

Date: November 2016

Industry Sector: Aerospace

Type of Work: Wire Erosion

Client Requirements:

We were asked by one of our aerospace customers to wire erode several components that are to be used in aero engine blade manufacture.  This included 2 x 2 Wire erode inserts, 2 operations roughing cut and 2 operations finishing cut. This was not a straight forward job as the material used was a steel alloy that was extremely expensive and very tough to machine conventionally.

Work Carried Out:

Utilisation was critical as the material is expensive so there could be no room for error.  We received the blanks in the form of a large cheese wedge (see photos) with a large angled top face.  We set up blocks after firstly EDM chilling a stat hole.  The component requirements for this project involved multiple operations.  An initial set of cuts leaving a 4mm allowance was made.  Due to the nature of the material, the amount of material that had to be removed, and the complexity of the profiles, stress relieving was carried out.  This was followed by secondary finishing cuts that were made according to the drawing sizes.  Further operations were then undertaken using our EDM die sinking machine in order to produce other complex and difficult to machine details. This was a very complex profile which meant that very little conventional machining took place on the finished parts.”

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