EDM LASER STEM Drilling

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1 EDM LASER STEM Drilling The Next Generation...

2 Welcome to TEK4 TEK4 is a world leader in drilling technology for cooling holes as applied to Jet Engines and Gas Turbines for energy production. TEK4 was established in 2002 and will be trebling its premises in Leicestershire during 2018 to accommodate a new showroom, research centre and increased production capability to satisfy international demand. TEK4 specialises in EDM (Electrical Discharge Machining) for fast hole drilling; combined EDM and Laser machines for hole drilling and ceramic coating ablation; LASER for drilling and cutting operations; and ECM for STEM drilling deep cooling holes in Gas Turbine components. All TEK4 s machines are designed and manufactured in Leicester, UK. TEK4 can also offer customer in-house process development, turnkey solutions and process application innovation. TEK4 s team of design, software, mechanical, electronic and application engineers gives us the ability to offer total in-house solutions. TEK4 products include MHD EDM Multi Hole Drilling FHD EDM Fast Hole Drilling LASER Drilling System STEM Drilling ECM Turnkey solutions Technical consultancy

3 Designed for aero components 6g FHD AERO Fast Hole Drill EDM Machine 6g FHD AERO The 6g FHD Aero is specifically designed for aero components, engine blades and vanes. TEK4 s latest 6g platform FHD EDM Drill has market leading performance and a compact footprint allowing Paint to Paint placement of machines. 6g Key Features Outstanding EDM Performance Automatic guide and electrode changing Inbuilt CMM probe 6g easy to use operator interface Best in class metallurgy Laser Ablation - Drill After Coating (optional) Rapid Shaped Hole Drilling Advanced Break Through X AXIS STROKE 300mm Y AXIS STROKE 300mm Z AXIS STROKE 400mm EDM AXIS STROKE 600mm A AXIS 360 ± 180 B AXIS 360 CONTINUOUS Tool Store Guide 10 Standard Tool Store Electrode 20 Standard

4 6g FHD EDM Systems Designed for medium to large components 6g FHD ST Fast Hole Drill EDM Machine 6g FHD ST The 6g FHD ST is the latest generation of our medium sized cross over machine. It has been specifically developed for hole drilling of small to medium sized aero parts, IGT blades, segments and other components. It offers flexibility for a range of applications. 6g Key Features Outstanding EDM Performance Automatic guide and electrode changing Inbuilt CMM probe 6g easy to use operator interface Best in class metallurgy Laser Ablation - Drill After Coating (optional) X AXIS STROKE 700mm Y AXIS STROKE 300mm Z AXIS STROKE 400mm EDM AXIS STROKE 400mm A AXIS 360 ± 180 B AXIS 360 Tool Store Guide 4 Standard Tool Store Electrode 8 Standard

5 Designed for large gas turbine components 6g FHD XXL / GXL Fast Hole Drill EDM Machine 6g FHD XLL The 6g FHD XLL is TEK4 s large machine specifically developed for drilling and laser ablation on large gas turbine components. The machine s configuration enables larger than expected components to be machined in a single set up. 6g FHD GXL 6g FHD XLL 6g FHD GXL This is TEK4 s largest machine. It has been specifically developed for hole drilling of very large gas turbine components. 6g Key Features Outstanding EDM Performance Automatic guide and electrode changing Inbuilt CMM probe 6g easy to use operator interface Best in class metallurgy Laser Ablation - Drill After Coating (optional) X AXIS STROKE 1000mm 1000mm Y AXIS STROKE 500mm 800mm Z AXIS STROKE 635mm 800mm EDM AXIS STROKE 915mm 915mm A AXIS 360 ± ± 180 B AXIS Tool Store Guide 10 Standard 10 Standard Tool Store Electrode 14 Standard 14 Standard

6 6g FHD EDM Drill Technology 3 Steps to Accuracy Assurance Set The Machine 1 Using the CMM probe integrated within the machine, all axis are checked for positioning accuracy, the datums are set and the part pallet chuck geometry is checked. Time taken: 3 minutes. Set The Electrode 2 The electrode position is measured to the machines datums and tool offsets are automatically applied. This eliminates any tooling errors. Set The Part 3 Using the inbuilt CMM probe, the part is measured at its reference points and is then nested by the software using a (Plane, Line, Point) approach. It is then rechecked by the probe with the 3D compensations applied. TEK4 s Tooling TEK4 s new tooling system includes in-built through-flushing, high accuracy and repeatability guides and holders. TEK4 s curved guides allow for non-line-of-sight drilling. Unlike other manufacturers, TEK4 s tooling is extremely simple, making it both reliable and cost effective.

7 5 Essential Core Technologies EDM Class leading EDM performance 1 TEK4 s PulseTech EDM technology is specifically designed for rapid EDM hole drilling in Aero and IGT parts. Flexible parameter process programming and adaptive software combine to give outstanding performance. Pre-Break Through Detection 2 Pre-Break Through Detection automatically detects the onset of the beginning of electrode break through. Once detected, EDM parameters are automatically engaged to improve and speed up the electrode break through. This is particularly valuable on acute angles and also compensates for casting thickness variations. Automatic Break Through Detection 3 A programmable Break Through Detection system is used to prevent electrode overrun, especially when breaking into small cavities. Break Through Detection compensates for casting variations and improves quality. Advanced Shaped Hole Capability 4 TEK4 s Shaped Hole Technology combines accuracy and flexibility with process speed. TEK4 s latest shaped hole drilling uses AFC (Advanced Feedrate Control) which brings 30% improvement in shaped hole drilling times. Data Collection 5 Each drilled hole application has a distinct process finger print. This is the sum of all the process variables. By graphing this process, improvements become immediately clear and by comparing current performance to previous performance process stability can be ensured.

8 6g Control System TEK4 s latest user interface has been completely updated and re-designed, enabling TEK4 s advanced features to be easily accessible and programmed. The latest generation control system has advanced connectivity allowing real time data gathering and remote status monitoring. The new control system has on screen documentation providing manuals, training videos and customer machine care videos. Key Points User Friendly On Screen Manuals On Screen Training and Customer Machine Care Videos Connectivity Remote control; Remote Data Analysis; Remote Status Monitoring LASER ABLATION DAC TEK4 s optional Drill After Coating (DAC) technology, uses a high frequency fibre Laser to remove non-conductive coatings on components. This technology is confined within the FHD EDM machine allowing for a single operation solution to drill after coating. Key features High Frequency Fibre Laser High Speed Accuracy Head Automatic Calibration 100w Laser Power Single Operation Dual Process

9 6g MHD EDM Drill TEK4 s Multi Hole Drilling (MHD) EDM Machining Centre is for producing multiple cooling holes in turbine blades and vanes. The system has capability to produce straight, shaped and slotted holes. The dielectric can either be traditional oil based fluids or de-ionised water for rapid machining rates. The multi mode PulseTech EDM generator allows optimised use of tungsten, graphite, brass and copper electrode. The programmable generator allows for full parameter control during the EDM cycle and the ability to change process parameters with depth, thus optimising the process in all areas of the cut. A two axis system allows for shaped holes to be produced using standard rod type electrodes. The system is designed for volume production. Use of cassette type tooling enables rapid change-over between operations. The tank fill time of 8 seconds and drain time of 4 seconds minimizes non cutting time on this production system. Key features Break Through Detection Programmable Generator Process Data Logging printout Fan Shaped Holes Auto fast fill and auto drain Integrated compact construction High response DC servo Automated operation Specification Z axis 200mm Z2 axis 40mm drill stroke X axis 5mm(Fan stroke) 32 Electrode channels 50Amp output 500 Generator programs

10 5g LASER Systems THE 5g GX Laser is class leading Outstanding Flexibility The 5g Laser systems are designed specifically for machining turbine components. The machine configuration enables larger than expected components to be machined in a single set up. Process flexibility The TEK4 5g Laser systems are able to Percussion Drill, Trepan Drill, Cut, Drill and Weld all in one set up, by switching processes using program parameters. This enables several processes to be used within a single automatic cycle. Measuring system The inbuilt measuring system gives huge flexibility, allowing parts to be simply fixtured and then letting the machine find the datum points. This enables compensation to be made for part variation, ensuring components are loaded correctly before machining and so reducing scrap.

11 LASER drilling-cutting-welding TEK4 s fifth generation of LASER systems provide exceptional performance, rugged stability and straight forward user friendly approach. Each machine features a single beam delivery mirror for ease and stability of beam alignment. All machines are fitted with a measuring touch probe for machine calibration and component location and compensation. Key features Auto calibration In built probe system Erowa chuck fixture location Cassette optics Large capacity + compact machine Pendant operator control Class leading performance Drill, Cut, Weld in one set up User friendly control Simple beam alignment Auto beam calibration Auto machine axis calibration Camera repair technology Machine type X axis mm Y axis mm Z axis mm A axis º B axis º Max part weight kg Max part diameter mm 5g ST Laser (+/ g XL Laser (+/ g GX Laser Beam Wrist (+/

12 5g LASER SystemTechnology 3 Steps to Accuracy Assurance Set The Machine 1 Using the CMM probe integrated within the machine, all axis are checked for positioning accuracy, the datums are set and the part pallet chuck geometry is checked. Time taken: 3 minutes. Set The Beam 2 The fully automated Beam Set cycle enables the position and focus point of the Laser beam to be located and locked in to the control system. This is often a long and skilled process on other systems. Set The Part 3 Using the inbuilt CMM probe, the part is measured at its reference points and is then nested by the software using a (Plane, Line, Point) approach. It is then rechecked by the probe with the 3D compensations applied.

13 4 Essential Core Technologies Amazing access and ease of use 1 TEK4 s Laser systems are carefully designed to allow easy access for component loading and new application development. All machines have innovative enclosure designs that maximize operator access and functionality. Powerful control system 2 The 5g Laser control panel offers high performance 5-axis control combined with a simple user interface. Operator training is rapid and intuitive. Switching between Laser process parameters is very simple as established process parameters are saved as process tools that can simply be called up with the CNC program. Process flexibility 3 TEK4 s advanced YAG Laser head has a huge process range offering flexibility between very high peak power pulses for drilling through thick sections, to high frequency low energy pulses ideal for rapid trimming of thin material. Advanced optics 4 Each TEK4 5g Laser system comes supplied with a crash protection system that allows 3D deflection in a crash and breaks the axis movement. Cassette draws allow fast and precise changing of the lens and cover slide optics.

14 estem Drill CNC 1000A STEM Drill Key features 4th generation design 700mm Z stroke 1500mm daylight 800x800mm work table 1000 Amps Integrated acid system Process monitoring Process finger printing 100 process programs Advanced filtration Single screen control Stainless Steel construction Great access Large capacity Process data logging USB interface A new generation STEM (Shaped Tube Electro-chemical Machining) system that overcomes the negative aspects of the process. This system is a single unit machining centre enclosing the process and the acid systems in a single unit. This means that the machine is easy to install and there are no acid leaks because all the tanks, pipe work, filters, pumps and valves are enclosed within the machine. The TEK4 estem incorporates many new features including advanced process control and better acid control. The control system has advanced process monitoring and graphing capabilities enabling process finger printing and tighter control of process variables. The TEK4 estem machine is entirely constructed from stainless steel for easy maintenance and longevity.

15 Unique purpose designed STEM control system, with advanced features including process monitoring and process finger printing. In-machine acid plant. This eliminates acid leaks. Advanced filtration, programmable temperature and pressure control. Fully flexible Turbulated Hole capability for increased cooling efficiency. Special simplified sub program for easy creation of Turbulated Holes. Front and rear sliding door for easy access. Swivel operator control panel for easy operation. Large working area allows for simultaneous machining of multiple large components. Stainless steel construction for a long life.

16 Tel +44 (0) Web: Mandervell Road, Oadby, Leicestershire, LE2 5LQ, UK