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Delcam’s CADCAM software is at the heart of a hybrid repair machine by Hamuel Machinenbau.

The Hamuel hybrid machine is capable of re-manufacturing high-value metal components, such as turbine blades, in order to give them a second life instead of manufacturing new parts. 

The machine combines five technologies in one unit — five-axis CNC milling, laser cladding, robot polishing, inspection and laser marking. Any of these processes can be combined, as required by the particular project.

The Manufacturing Technology Centre in Coventry, a partner in the development, has been responsible for the 3D laser cladding element, which is essentially a welding-based method of additive manufacturing that allows high-integrity material to be deposited onto the part being repaired.  

A typical application for the machine is the repair of a worn blade on an impeller. Using a hybrid machine, it is possible to remove the damaged area by milling off the worn material and then build the material back up using the cladding technology.  A second machining operation, using high-speed five-axis milling, then produces the final shape, with a smooth transition between the original part and the new material. 

Key benefits

  • The Hamual machine offers a decisive cost advantage, in particular when high-value and complex-shaped components are concerned.
  • The equipment costs only a fraction of the price of a multi-machine repair cell, as well as saving on floor space.
  • Automatic methods developed by Hybrid Manufacturing Technologies allow the Hamuel equipment to change between manufacturing processes as easily as a conventional machine can change between milling cutters. Changeover takes less than ten seconds typically and can be called up during any part program using only a few M-codes.
  • The machine’s laser cladding can be carried out with virtually all conventional welding metals, with the focused heat input allowing cladding of even difficult-to-weld materials.
  • In-cycle part inspection, using Delcam’s adaptive machining software, provides feedback to orientate the parts, assess defects, and ensure accuracy throughout the various stages.
  • The adaptive machining software customises the NC program to repair each component on an individual basis.
  • Laser cladding allows super alloys to be used for specific sections of the blade profile to enhance the performance and improve the properties of the component. 
  • The ability to undertake multiple processes without having to remove the part from the machine supports higher precision, repeatability and reproducibility.

Delcam supplies software and services that help manufacturing companies to maximise their profitability by increasing productivity, improving quality and reducing lead times. The company is the world's largest specialist supplier of computer-aided machining software, with its PowerMILL, FeatureCAM, Partmaker and ArtCAM programs making up the most comprehensive range of CAM systems from any developer.

This broad selection allows Delcam to offer a CAM system capable of machining virtually any product, in any material on any type of equipment. Delcam also develops product design, tooling design and quality control programs. The unique Tribrid Modelling approach to design incorporates solid modelling, surface modelling and triangle modelling in a single program, enabling complete design and reverse engineering projects to be undertaken without transferring data between software.

Delcam's Powerinspect offers fast, reliable comparison of parts, prototypes and tooling against CAD data on all types of inspection equipment and even on machine tools. This versatility has made it the world's leading hardware-independent inspection software. Related programs are available for checking machine tool set-up and part location. Delcam software is used in over 80 countries worldwide by around 40,000 organisations, from large multi-nationals to small sub-contractors, in industries including aerospace, automotive, dental, engineering, footwear, medical and toolmaking.

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