LX 051

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LX 051

The highest levels of process reliability and efficiency, thanks to individual application-orientated technology services

A comprehensive integrated solution from one source – from the machining system via the specially developed CAM system through to the integration of process monitoring systems

The optimisation of unit costs for ready-to-install blades thanks to an integral machining concept for pre and postprocessing in a clamping position

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Turbine Blade machining center

The LX series was specifically designed for the high-precision, efficient five-axis machining of turbine blades. This ultra-modern machining platform is the result of decades of experience in the development of machine tools, CAM systems and special tools combined with our in-house expertise in the prototype and series production of turbine blades.

Axis configuration

Innovative Solutions

  • Contour fidelity during high-speed machining through look-ahead feature and dynamic preselection
  • Drive parameter adjustment depending on the machining
  • Control cabinet with air conditioning unit
  • Control behavior and NC path planning are developed and optimized in great detail to achieve the perfect combination of geometrical accuracy, surface quality and of course productivity.
  • Depending on the required application, the machine can be optimally configured using five settings: roughing, pre-finishing, fast finishing, finishing and super finishing.

Process analyses and stability evaluations can be made easily with integrated sensors and evaluation routines. Collision damage is significantly reduced thanks to rapid crash detection and machine stop. This is an excellent addition to Starrag’s simulation solutions to avoid expensive machine downtime. The balancing quality of all tools and the state of the spindle bearings are automatically monitored.

  • Universal vise for bar stock and forged blanks
  • Very short clamping to reduce material consumption
  • Specialized clamping on tip side prevents deviations due to release of material stress
  • Workpiecechanger for convenient preparation of raw material parallel to processing time
  • automatic check of raw material length during AWC for enhanced process security
  • Optimized swarf flow directly into the chip conveyor
  • designed for wet or dry machining
  • emission extractor
  • Starrag connect
  • rotating disk window
  • conditioning unit for compressed air
  • Camera system
  • handheld unit
  • compresser temperature cooling unit
  • increased geometric accuracy
  • remote diagnosis
  • warm up program
  • energy efficiency
  • Symmetrical axis arrangement ensures an optimal distribution of the masses for all workpiece dimensions
  • Minimized and balanced movement of the masses
  • Short distribution of forces increases rigidity, leading to stable ratios during the machining process. These factors have been proven in real-time simulation during the machine development phase
  • All base frame components are designed using FEM analysis for maximum rigidity"
  • any component requiring periodic service are easy accessible
  • replacement items e.g. filters, wipers etc are easy to access
  • machine components require service are simply to access and repair
  • safe working areas for maintenance personal e.g. platforms and attach point are provided
  • condition based machine monitoring to predict future component failure

The special work-piece geometries create specific demands on the clamping fixtures. Starrag has in-house specialists who develop individual clamping concepts to meet the specific requirement of blade machining. Starrag offers the following advantages:

  • A single adapter design solution for all LX machine sizes using vices (at the hub) and hydraulic clamping jaws (at the shroud)
  • Clamping jaws can be implemented in a flexible way both for raw and for premachined surfaces
  • Distortion free machining due to flexible changeover between centrically and floating clamping
  • Starrag solutions enable distortion and indentation free clamping on freeform surfaces for the manufacturing of unstable blades
  • Geometric deviations between multiple fixtures can be stored in the control system. Measuring of blanks can therefore often be eliminated

Work piece measuring

  • Intuitive and easy to use, fully integrated into RCS CAM System
  • consistent integration of CAM system
  • probing
  • automatic adjustment

Highly recommended for a reliable and accurate production

  • zero reject rate

Tool measuring

  • Detection of tool breakage
  • enhanced process stability
  • avoiding machine collision

Measuring of tool length and radius

  • enhanced process accuracy
  • enhanced process stability

Detection of incorrect operation

  • avoiding machine collision

One key factor to lowest tool cost and highest productivity is the right process cooling. The LX machine series offers all state-ofthe- art through-spindle cooling options:

  • High pressure coolant (water-based or oil)
  • Through spindle air
  • Aerosol (minimum quantity lubrication)
  • CO2 cryogenic cooling through the spindle
  • Aerosol plus CO2 through spindle

Of course external cooling with coolant or CO2 is possible too. With these options, breakthroughs in tool life can be achieved, leading to the lowest overall cost.

Tool magazines with 60 or 80 pockets. Tool storage is expandable up to 320 tools ( HSK-A63)

  • Fast connectors to reduce time for spindle change
  • Starrag made spindle
  • Monitoring of vibrations, displacements and temperatures
  • Compensation of displacements for better process reliability
  • Spindle interlock for mill-turning
  • The rotary axes are directly driven by state-of-the-art torque motors
  • Guarantees the most precise positioning
  • High torque even at low speed
  • Highest possible rigidity for maximum dynamics
  • Power transmission free of backlash and extended service intervals
  • No mechanical component wear
  • Driven tip station with controllable torque
  • Large door and viewing window
  • Easy loading with crane
  • Transportation as a complete unit, with all auxiliary units fully integrated within the machine

Technical Data

Max. distance between centers mm 565
Swing Diameter mm 400
X-Axis mm 650
Y-Axis mm 650
Z-Axis mm 680
A-Axis (Root Station) degree 360 endless
AA-Axis (Tip Station) degree 360 endless
Swivel B-Axis degree -90 / 50
Linear Axes X Y Z U/min 62
Rotary Axis A U/min 200
Rotary Axis B U/min 60
Linear Axes P mm 0.006 (0.004)
Linear Axes Ps mm 0.0024 (0.0020)
Rotary Axes P sec 6.0
Rotary Axes Ps sec 4.0
Power at 100% Duty kW 28
Torque at 100% Duty Nm 181
Speed U/min 18000
Tool Taper HSK-A63
Max. Tool Weight kg 10
Max. Tool Diameter mm 100
Max. Tool Length mm 250
Standard / Max number of Tools 40 / 60 / 80 / 320
Tool Chancing Time sec 4.5
Max. Workpiece Diameter mm 400
Total weight (part and fixture) kg 50
Workpiece Change Time sec ca. 30
Weight kg 13000
Lenght x Width x Height mm 5200 x 3100 x 3110
Safety Concept CE-compliant
Siemens 840D Siemens 840D

Unmachined parts go in, finished parts come out

Starrag FMS enables fully automated turbine blade production

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Interview of WTB blade line retrofit

Wuxi Turbine Blade Co., Ltd. (WTB)

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AECC Chengdu Engine Co., Ltd.

The introduction of Chengdu Engine history

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Adaptive manufacturing of turbine blades

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Service Plus Package

Perfect service for perfect machines

Precondition for above-average productivity, efficiency and economy is a constant high availability of the machine. And necessary for this above all, besides innovative technology, is: A tailored service, which is perfectly coordinated to your individual requirements.

ServicePlus guarantees you machine availabilities of at least 95%!

Troubleshooting

Our call center staff immediately understands your service requirements and passes them on quickly and appropriately to our technical hotline or to the appropriate service advisor.

Starrag Hotline: +49 371 836 23 68

All Service Products

Spindle overhaul

Overhaul concepts tailored optimally to your requirements

Training courses

Efficient machine operation thanks to optimal training courses

Replacement parts

Fast and reliable supply of replacement parts due to global logistics network

Maintenance

High technical availability through preventive maintenance

Service near you

Time is money! That also applies when it concerns the service and maintenance of your machine. The Starrag Service and Logistics Centres near you have the necessary infrastructure, in order to guarantee you perfect service.

Service Contact

Partnering for Efficiency

Service Plus

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I have been informed that I can withdraw my consent to the processing of my personal data at any time. Withdrawal shall not affect the legality of any data processing already carried out before withdrawing my consent. By providing my consent, I confirm that I am aged 16 years or older. I hereby consent to the processing of my data. I give my consent voluntarily. I know that this declaration of consent will be saved.