GrindForm: A novel high performance manufacturing concept for ”difficult to machine alloys”

Important results from the project

The main goal of the GrindForm project was to investigate a new advanced manufacturing concept for aero engine components through deep grinding and hydroforming. The project has shown that each manufacturing method provide desirable advantages compared with current manufacturing, milling, but certain actions need to be handled.

Expected long term effects

The project´s objective was well fulfilled where the verifying investigations of each manufacturing technology clearly showed the advantages and disadvantages of the technology. The properties of the starting material were also identified to give a clear impact on the subsequent processing operations.

Approach and implementation

The project was carried out in two activities to study the impact of each technology on the work piece material and a third activity where the entire production flow was evaluated. The grinding was found to give a clear improvement both in terms of deformation of surfaces but also residual stresses. For the selected geometry, hydroforming provides the opportunity to reach the final shape where the finished component has generally low residual stresses. In summary, the manufacturing concept show great potential, but process optimization remains before finished geometry is obtained.