5-Axis CAM Programming for Impeller Machining
Development of stable 5-axis milling processes for impellers in compressor, pump, and turbomachinery applications. Focus areas include collision-free toolpaths, consistent cutting conditions, and repeatable implementation on the shop floor.
Services for 5-Axis Machining of Open Impellers
Keller Aerotech develops and optimizes 5-axis milling processes for open impellers with emphasis on stable, repeatable workflows in both production and prototype manufacturing. Goals include process stability, cost-effectiveness, defined surface quality, and production-ready implementation on real production machines.
- 5-axis milling strategies for freeform and ruled surface blades
- Material-specific process strategies for aluminum, steel, and high-temperature alloys
- Finishing strategies with controlled contact points along blade profiles
- Reduction of vibration, air cuts, and unnecessary machine movements
- Technical support through stable transition into series production
Technical Focus & CAM Expertise
Open impellers place high demands on CAM strategy, tool selection, and overall process design. Key focus areas include:
Geometry & Accessibility
Freeform surfaces, difficult accessibility, and large length-to-diameter ratios require toolpaths with controlled approach angles and smooth, continuous axis movements.
Advanced Technologies
Trochoidal roughing strategies for constant cutting conditions and strategic use of barrel cutters for finishing operations where flank milling is not geometrically feasible.
Surface Quality
Uniform toolpaths, controlled contact points, and minimized transition marks on blade surfaces, hub, as well as leading and trailing edges.
Process Reliability
Repeatable operations and stable processes with controlled tool wear to prevent tool breakage, even in difficult-to-machine materials.
Cost-Effectiveness
Beyond cycle time, factors such as tool consumption, tool life, and process stability influence cost per part. Focus is set according to customer-specific project and production requirements.
Typical Applications
Open impeller programming is particularly applicable where high geometric complexity, tight tolerances, and stable, repeatable production processes are required.
- Open impellers for compressors and turbines in aerospace, automotive, and industrial turbomachinery applications
- Program development for prototypes and production-ready NC strategies
- Optimization and stabilization of existing machining processes
- Technical support and capacity relief for internal CAM departments
Collaboration & Contact
Collaboration is project-based, confidential, and technically focused. Services range from component geometry analysis through to fully developed and validated NC strategies.