A hole-drilling solution combining laser, EDM capabilities

As aerospace and industrial gas turbine manufacturers strive to improve performance, the need for high-quality hole drilling of turbine engine components is rapidly becoming mission-critical. To address this need, Synova and Makino are joining forces to offer a unique solution, the HybridCell, which combines the power of Synova's Laser MicroJet® (LMJ) with Makino's leading edge EDM capabilities. It is a fully automated, manufacturing-ready, work cell that can handle a wide range of hole-drilling applications.

The HybridCell consist of a MCS 500 cutting system, along with Makino's EDBV EDM hole-drilling machine.

"Combining Synova's MCS 500 Laser MicroJet machine with Makino's well established hi-speed EDBV machines enables our customers to drill holes in components already pre-coated with a thermal barrier, as opposed to post-coating drilling processes currently being used. This approach significantly simplifies the overall process, improves quality and reduces overall manufacturing", says Dr Bernold Richerzhagen, Synova Founder and CEO.

The Laser MicroJet system is used to cut diffuser shapes in the coating layer and drilling metering holes, while the EDBV is used to drill deep through holes. The machine tasks are easily balanced between the HybridCell machines, ensuring an optimum throughput. An innovative solution is provided to handle difficult "non-line of sight" holes on the EDM machine. A sophisticated data transfer scheme is also part of the cell, enabling high accuracy hole-drilling of complete components.

All EDM drilling on EDBV machines is performed while being fully submerged under water. This enables faster machining speeds, improves part quality, and creates more stable and consistent conditions during cavity wall penetration. Speeds up to 10 times that of conventional technologies are achieved.