Experiences from a Quantum Leap Improvement in Turbine Manufacturing

Abstract

Abstract:This paper discusses experiences from a research project aiming at the improvement of the machining process for Hydro Power Plant Turbines. Both technical results and experiences from the process to achieve these results are expressed. A number of improvement features regarding 5-axis machining of sculptured surfaces are discussed. Major findings are pointed out as the lack of suitable functions in the CAD/CAM system to cope with the challenges of this· specialised product. Improved machining strategies as "Parallel Cut", "Constant Gap Strategy", and "Multi-axis Plunge Cutting" are introduced. The outcome of the project was a new method for manufacturing of turbines. Based on the experience in the development project, reflections regarding organisational mechanisms for Quantum Leap Improvement are discussed.