An apparatus and method are provided for three dimensional cutting of a multi-axis feature into a workpiece that are at least partially characterized by a lack of rotationally symmetrical tools and an ability to produce high aspect ratio (depth to diameter) features using mechanical machining. The apparatus includes a base, a displaceable machine table supported on that base, a displaceable spindle supported on the base adjacent the machine table, a cutting tool held in a chuck carried on the spindle and a control module. The control module includes a controller and a plurality of actuators to provide precise displacement of the machine table, spindle, cutting tool and the workpiece for cutting multi-axis surface features into the workpiece.

A method for milling a workpiece by way of at least one substantially polygonal cutting insert, which is arranged in a tool holder. A spindle axis of the tool holder encloses an angle of more than 0° with a plane normal to a machined workpiece surface. An effective lead angle between a main cutting edge of the cutting insert and the machined workpiece surface lies between 0° and 20°.

After a free-form surface is machined on an elongated material 1 with a projection 3 and a blade root 4 held, the holding of the projection 3 is released to release strain generated during machining. Upon release of the holding, the entire elongated material 1 deforms, and the projection 3 moves from a holding position A to a strain-released position B. A re-holding position C obtained by correcting the position B by the deformation amount of the elongated material 1 due to the weight of the elongated material 1 is determined, and the projection 3 is held again at the re-holding position C for further machining the free-form surface on the elongated material 1.

A method and apparatus for the refurbishment and repowering of wind turbines through the extension of existing installed blades so that they can catch more wind energy and therefore enable an increase in the overall average power output of the wind turbine.

A method for manufacturing a thin-walled part having curved surfaces, in particular a turbine blade by a machine tool comprising roughing process and semi-finishing process. At least one of the roughing process and the semi-finishing process is accomplished by flank milling.

A method for manufacturing a stage of a steam turbine comprising the steps of milling a block of material to define a sector having a plurality of blades, each blade having an external surface; machining an opening in the external surface of at least one of the blades; machining a cavity in fluid communication with the opening; the step of machining the cavity being performed by wire electric discharge machining.

A method for machining a blade and a blade for a turbomachine comprising a shroud which is positioned on a tip side of the blade. The shroud has an outer surface with at least one circumferential fin arranged thereon, whereby at least one section of the outer surface beside the at least one fin is processed in at least two manufacturing steps. At least one first section of the outer surface is processed to have a first shape and at least one second section of the outer surface is processed to have a second shape.

A processed article is manufactured with a tool including a cutting blade. The cutting blade is arranged to be in contact with two machined segment surfaces so that two contact points are defined between the two machined segment surfaces and the cutting blade in a corner. A machining pitch is set in a pick feed direction of the tool at the corner to a first machining pitch for when a part of the cutting blade corresponding to a projected shape of a side surface of the cutting blade having a first curvature radius is a cutting point. A cut is performed along a feed direction in the two adjacent machined segment surfaces successively at the corner so that the tool proceeds toward the corner in one of the machined segment surfaces and away from the corner in the other one of the machined segment surfaces.

The invention relates to a method for producing a blisk comprising a plurality of blade profiles and channels extending between the blade profiles using a bell-type countersink having a conical lateral surface, wherein the method comprises the steps providing a disk-shaped blank, and, to form the channels in the blank, plunging the bell-type countersink into the blank on a lateral surface of the blank and thereby moving it in a direction along a generating line of the bell-type countersink, wherein the displacement of the bell-type countersink is a 3-axial movement on a linear path and/or a 5-axial movement on a curved path. The invention also relates to a bell-type countersink.

Methods for manufacturing a tandem guide vane segment that includes an outer platform, a front guide vane, and a rear guide vane, wherein the front guide vane and the rear guide vane are arranged in a firmly fixated manner with respect to one another. One method includes manufacturing an integral front segment section that includes the front guide vane and a front section of the outer platform, manufacturing an integral rear segment section that includes the rear guide vane and a rear section of the outer platform, and connecting the two segment sections to each other.