MANUFACTURINGOFSTEAM TURBINEBLADE

AvisittoQualityprofilespvtltd,patancheru was carriedoutandinformationregarding manufacturingbladewascollected.Afterthatwe manufacturedbladeaccordingtospecificationswith thehelptechnicianoverthereonCNC3AXIS MACHINE.

CNC INTRODUCTION
Inordertomeettheincreasingdemandtomanufacturecomplicatedcomponents ofhighaccuracyinlargequantities,sophisticatedtechnologicalequipmentand machineryhavebeendeveloped. ThedesignandconstructionofComputerNumericallyControlled(CNC)machines differsgreatlyfromthatofconventionalmachinetools.Thisdifferencearisesfrom therequirementsofhigherperformancelevels. Thecontrolofamachinetoolbymeansofstoredinformationthroughthe computerisknownasComputerNumericallyControlled.Theinformationstored inthecomputercanbereadbyautomaticmeansandconvertedintoelectrical signals,whichoperatetheelectricallycontrolledservosystems. ComputerNumericallyControlcanbeappliedtomillingmachines, Lathe machines,Grindingmachines,Boringmachines,Flamecutters,Drillingmachines etc.

MANUFACTURINGPROCESS
Thedifferentprocessesfollowedinthemanufactureofsteamturbinebladeoncnc3axis machineasfollows 1.RAWMATERIALPROCUREMENT: Thesteamturbinebladematerialisprocuredasperthedesignspecification.The materialisinspecteddimensionallyandallthemechanicalandchemicalanalysisaremadeas perthespecification.

fig.1

2.LENGTHCUTTING: Thematerialiscuttolengthbykeepingmachiningallowanceatbothends eitherbyBandSaworbyPowerHackSaw. 3.THICKNESSMILLING: Thematerialisclampedinaviceorfixtureandthicknessismilledonboth sidesbykeepingnallowanceof0.5mmonbothsidesforgrinding.Thisoperationis doneeitherbyhorizontalmillingmachiningorbyverticalmillingmachine.

Fig.2

fig.3

4.THICKNESSGRINDING: Themilledbarsaredeburredandkeptonamagneticchuckofthe segementalsurfacegrindingmachine.5to10bladesarekepteachtimedepending onthesizeandgroundeachsidetomaintainthedimension.Thetoleranceonthe grindingdimensionswouldbe+/ 0.05mmandparallarithshouldbewithin0.02 mm. 5.RHOMBOIDMILLING: Thegroundbladebarsaremilledtorhomboidshapewithananglegiven intheprocessbyclampinginafictureonbothsideswithanallowanceof0.5mmon bothside.Thisisdoneonthehorizontalmillingmachines.

Fig.4

Fig.5

6.RHOMBOIDGRINDING: Themilledbarsaredeburredandkeptonmagneticchuckofthesurface grinderandgrindingisdoneonbothsidesandthetoleranceshouldbe+/ 0.05mm.The surfacemustbewithin8microns. 7.FACINGANDSIZEMILLING: Thegroundbladesarefacedontherootsidetomaintainperpendicularity.Thisis veryimportantasthebladeisheldonthisfacewhileinassembly.Thenonothersidesize millingisdonetomaintainthetotallengthofbladesasperthedrawing.

Fig.6

8.ROOTMILLING: Clampthebladeinaviceorfictureandmachinetherootonbothsides asperdrawingkeepinganallowanceforrootradius.Donotmachine2bladeas theseareusedforlockingpurpose.Thisoperationisdoneonhorizontalmilling machine. 9.ROOTRADIUSMILLING: Clampthebladeinaviceorfixtureandmachinetherootradiusas perdrawingbyCNCMachingcenter.ThisoperationisdoneonCNCVertical machiningcenterbyCNCProgram.

Fig.8

10.WIDTHMILLING: Theprofilewidthisdoneonbothsidesonhorizontalmillingmachineasper thedrawing. 11.CONVEXMILLING: Themillingisdoneonconvexsidebya CNCmachiningcenter.TheCNC Programisdevelopedbasedontheprofilecoordinatesandthenloadedintothe CNCsystemofthemachine.

Fig.10

Fig.11

12.CONCAVEMILLING: TheprofilemillingisdoneonconcavesidebyaCNCmachiningcenter.The CNCProgramisdevelopedbasedontheprofilecoordinateandthenloadedin totheCNCsystemofthemachine. 13.TAPERMILLING: Thetapermillingisdoneonahorizontalmillingmachinebyputtinginafixture speciallymade.Thetaperiscalculatedfromsinevaluesandmachined accordingly.

Fig.12

14.TAPERGRINDING: Thetapergrindingisdoneonasurfacegrindingmachioneandensuretheanglewithin thegiventoleranceinthediagram.Alsosurfacefinishmustbewithin8microns. 15.FITTINGANDPOLISHING: Thebladesaredeburredandroundedoffontheinletsideandthenpolishedonblade polishingmachine.

Fig.14

Fig.15

CONCLUSION
Asweunderstoodthattheefficiencyandreliabilityofasteam turbinedependsontheproperdesignofblades. Thereliabilityofmovingbladesistobeensureduponproper designselectionofmaterial. Inbladeprofilewhereasinimpulsetheentireheatsdrop occursinstationaryblades. TheforkroothashigherloadcarryingcapacitythanTroot. Differentmillingcuttersareusedtofinishtheoperationon theblade. Thegrowthforthesteamturbinesareveryhighanddemand forbladesisgrowing.

THANKINGUSIR
B.DEVENDERPRASAD 07241A0331 B.LOVARAJU 07241A0340 P.NITHISHREDDY 07241A0344