USOO6077002A

United States Patent (19) 11 Patent Number: 6,077,002

LOWe (45) Date of Patent: Jun. 20, 2000
54) STEP MILLING PROCESS 2,633,776 4/1953 Schenk.
2,703,511 3/1955 Griner ..................................... 409/198
75 Inventor: Donald D. Lowe, Bow, N.H. 2.962,941 12/1960 Stein et al..
3,130,481 4/1964 Ahlen.
73 Assignee: General Electric Company, Cincinnati, 3.370,508 2/1968 Iaia .......................................... 409/132
Ohio 4,046,057 9/1977 Imamura.
4,260,304 4/1981 Jacobi ..................................... 409/132
5,782,589 7/1998 Cole .......................................... 407/54
21 Appl. No.: 09/166,248
22 Filed: Oct. 5, 1998 Primary Examiner-Daniel W. Howell
Attorney, Agent, or Firm- Andrew C. Hess; Gerry S.
(51) Int. Cl. .................................................. B23C 3/18 Gressel
52 U.S. Cl. ...................... 409/132; 29/889.2, 416/223 A
58 Field of Search .............................. 409/51, 131, 132, 57 ABSTRACT
409/177, 198, 199; 407/34, 54; 29/889.7, A blank is milled using a rotating mill. A groove having a
889.6, 889.2, 416/223 A bottom is first cut across the blank to partially expose a
56) References Cited sidewall in the blank. The sidewall is then cut by the mill.
By alternately repeating cutting of the groove and Sidewall,
U.S. PATENT DOCUMENTS the groove is milled deeper in the blank to form a pocket
along which the sidewall extends. Since the sidewall is
1,744,757 1/1930 Ferguson. formed in Steps, improved efficiency and accuracy is
2,390,994 12/1945 Vlieg. obtained therefor.
2,429,324 10/1947 Meisser.
2,431,604 11/1947 Birmann.
2,480,807 8/1949 Vlieg. 10 Claims, 3 Drawing Sheets
U.S. Patent Jun. 20, 2000 Sheet 1 of 3 6,077,002
U.S. Patent Jun. 20, 2000 Sheet 2 of 3 6,077,002
U.S. Patent Jun. 20, 2000 Sheet 3 of 3 6,077,002

BLANK 1O

26

MLL
PASSES GROOVE

MLL
SDEWALL

REPEAT

3O

COMPLETE
POCKET

NDEX
BLANK

16

SIA
(SK2,
FG. 4 S
 6,077,002
1 2
STEP MILLING PROCESS approximate the 3-D shape of the individual airfoils with a
Suitable exceSS of material there around. This rough milling
BACKGROUND OF THE INVENTION uses a relatively large ball end mill which is plunged into the
The present invention relates generally to gas turbine blank in each pass over Substantially its full radius to
engines, and, more specifically, to milling of blisks therein. maximize material removal.
A turbofan gas turbine engine includes in Serial flow A Second Step in the proceSS uses a Smaller ball end mill
communication a fan through which ambient air is to Semi-finish the platform at the bottom of each pocket and
propelled, a multistage compressor for pressurizing a por provide Suitably Small radii with the freestanding rough
tion of the air, a combustor wherein the compressed air is airfoils.
mixed with fuel and ignited for generating hot combustion A third step uses yet another ball end mill of the initially
gases, and high and lower pressure turbines which extract large diameter to Semi-finish the pressure and Suction sides
energy from the combustion gases for powering the com of the individual rough airfoils in turn. The end mill typically
preSSor and fan, respectively. Both the fan and compressor circles each rough airfoil in multiple cutting Steps from the
include airfoils in the form of rotor blades which extend
15
outer tip to the inner root near the platform, and uses Suitably
radially outwardly from a rotor disk. The blades are free Smaller tolerances to produce a Semi-finish airfoil still
Standing or cantilevered radially outwardly from the disk having exceSS material.
and the centrifugal loads generated therein during operation A fourth step uses yet another, Small ball end mill to finish
must be carried by the disk within acceptable StreSS limits. machine the individual platforms at the bottom of the
A typical rotor blade is carried in the disk by an integral pockets to final dimensions with Suitably Small tolerances.
dovetail which Slides into a corresponding dovetail slot in And, the last Step in machining the airfoil blades uses yet
the perimeter of the disk. However, as the number of rotor another large ball end mill to finish machine the individual
blades around the perimeter of the disk increases in Some airfoils in turn by again circling the individual airfoils from
designs, insufficient material is available around the perim tip to root in multiple Steps or passes with Suitably Small
eter of the disk for supporting the several blades within the 25 tolerances to achieve the precise dimensions of the required
acceptable StreSS limits. airfoils.
Accordingly, blisks have been developed and are found in In another conventional manufacturing process, the indi
commercial use and are characterized by the absence of vidual airfoils may be rough and Semi-finish milled as in the
independent dovetails, with the blades instead being inte above process, with the final machining thereof being
grally joined to the rotor disk in a one-piece, unitary effected using electrochemical machining (ECM). ECM
assembly. In this way, fan or compressor bliskS may be used machining is precise and relatively quick, yet requires
in an engine for maximizing aerodynamic efficiency thereof expensive equipment which correspondingly increases the
while reducing the associated centrifugal Stresses in the cost of manufacture.
Supporting disk. In both methods, however, the individual rough airfoils
However, the manufacture of a blisk is substantially more 35 must nevertheless be semi-finish milled with a ball end mill
complex than the manufacture of individual rotor blades and which necessarily applies a contact force on the airfoils.
discrete rotor disks, and manufacturing defects therein Since the airfoils are freestanding or radially cantilevered,
involve a Substantially greater risk. If even one of the Several they inherently elastically deflect under the force of the
rotor blades being manufactured is outside an acceptable cutting mill, which must be accommodated in the milling
manufacturing tolerance, the entire blisk is defective and 40 process to avoid removing excessive material which would
must be Scrapped at considerable expense. Accordingly, the render the blisk defective. Airfoil flexibility is accommo
manufacture of a single blisk requires great care and atten dated by removing relatively little material in each pass to
tion to manufacturing tolerances which increases the time to minimize the elastic deflection of the airfoils, at a consid
manufacture the blisk, and correspondingly increases the erable increase in milling time. Since ball end milling cuts
cost thereof. 45 a Series of grooves along the Surface of the airfoil it leaves
For example, one conventional method of manufacturing intervening cusps which must be minimized in height for
a blisk includes a multistep point machining or milling achieving an acceptably Smooth final Surface contour of the
individual blades therein in turn. Since the individual blades preSSure and Suction sides of the individual airfoils.
have airfoils Specifically configured for their fan or com Furthermore, the individual blisk airfoils are individually
preSSor functions, the blades typically twist about a radial 50 milled and therefore additional manufacturing variations
axis from their roots to tips, have varying taper, and have occur Statistically from blade-to-blade. Since the resulting
generally concave pressure Sides with correspondingly blisk is a rotor component which operates at Substantial
opposite generally convex Suction sides. The complex three rotary Speed, it must be Suitably dynamically balanced
dimensional shape of the individual blades is precisely point during operation. Balancing is typically effected by provid
milled with a suitable cutter or cutting tool in the form of a 55 ing an annular balancing land near the hub of the disk from
ball end mill. This mill includes a Semispherical cutting end which material may be precisely machined for balancing the
attached to a cylindrical shaft which rotates the mill for entire blisk.
removing material in grooves from the blank in multiple However, the balance correction effected at the land
passes. necessarily has a limit which Sometimes may be insufficient
The point milling process typically includes a first Step of 60 in the event of exceSS Variation in final dimensions of the
rough milling individual pockets axially acroSS the perimeter several blisk airfoils. In order to balance Such a blisk,
of the blank between its opposite axial faces in Successive individual airfoils may require additional milling provided
Steps or levels until the pocket has a Substantially complete Sufficient material remains thereon in order to reduce the
depth. The blank is indexed to repeat the rough milling of the initial unbalanced condition of the blisk.
several pockets around the perimeter of the blank with the 65 Accordingly, it is desired to provide an improved process
remaining material between the blanks being freestanding, for milling gas turbine engine blisks with improved effi
radially outwardly extending cantilevers which roughly ciency and accuracy.
 6,077,002
3 4
BRIEF SUMMARY OF THE INVENTION plex 3-D milling paths through the blank 10 which is
A blank is milled using a rotating mill. A groove having accomplished in multiple Steps or levels radially inwardly
a bottom is first cut acroSS the blank to partially expose a from the perimeter of the blank 10 down to the hub 12 to
sidewall in the blank. The sidewall is then cut by the mill. define a resulting radially inner platform 24 between each of
the blades 18.
By alternately repeating cutting of the groove and Sidewall,
the groove is milled deeper in the blank to form a pocket The milling machine 20, the ball end mill 22, and the
along which the sidewall extends. Since the sidewall is blank 10 are all conventional in Structure and operation. AS
formed in Steps, improved efficiency and accuracy is indicated in the Background Section, the milling machine 20
obtained therefor. has been previously used in commercial production of blisks
for many years in multiple proceSS Steps of rough machining
BRIEF DESCRIPTION OF THE DRAWINGS individual blades, semi-finishing the individual blades and
platform, and finish machining the individual blades in a
The invention, in accordance with preferred and exem relatively complex, lengthy, and expensive milling process.
plary embodiments, together with further objects and advan In accordance with the present invention, the same con
tages thereof, is more particularly described in the following 15
ventional multiaxis milling machine 20 may be used in a
detailed description taken in conjunction with the accom new and improved process of milling the Same type of blank
panying drawings in which: 10 with Significantly improved efficiency and accuracy, and
FIG. 1 is a Schematic representation of a multiaxis milling with reduced time and cost. The Step milling process in
machine for point milling a plurality of circumferentially accordance with an exemplary embodiment of the present
Spaced apart pockets in the perimeter of an initially Solid invention is illustrated in increasing detail in FIGS. 2 and 3,
blank to form a gas turbine engine rotor blisk in accordance and is represented generally by the flowchart representation
with one embodiment of the present invention. shown in FIG. 4.
FIG. 2 is a elevational, partly Sectional view through a Referring initially to FIG. 2, the Step milling proceSS is
portion of the perimeter of the blank illustrated in FIG. 1 initiated by cutting an elongate groove 26 having an arcuate
showing a ball end mill initially forming one of the pockets 25
bottom to partially expose a Sidewall 28 Starting at the
therein. perimeter of the blank 10 by feeding the rotating mill 22
FIG. 3 is an enlarged, elevational end view of the mill transversely across the blank. The so exposed sidewall 28 is
illustrated in FIG. 2 cutting a plurality of grooves through then cut by again feeding the mill 22 transversely across the
the perimeter of the blank to form one of the pockets therein blank and along the previously cut groove 26. Then by
and taken generally along line 3-3. alternately repeating the groove and Sidewall cutting, the
FIG. 4 is a flowchart representation of an exemplary groove is step milled radially deeper in the blank and forms
method of step milling the blisk illustrated in FIGS. 1-3 in a corresponding pocket 30 along which the sidewall 28
accordance with an exemplary embodiment of the present extends.
invention. 35 More specifically, the lower end of the ball end mill 22 is
DETAILED DESCRIPTION OF THE
illustrated in more detail in FIG. 3. AS indicated above, the
INVENTION
ball end mill 22 is Semispherical in configuration with an
outer diameter 2R, and a radius R. A cylindrical shaft no
Illustrated schematically in FIG. 1 is a workpiece or blank larger than the outer diameter of the cutting end of the mill
10 in the exemplary form of a Solid annular disk having an 40 is operatively mounted in the milling machine for rotation
annular central hub 12 or inner portion of the disk from and feeding along any desired milling path as Suitably
which integrally extends a tubular shaft 14 in a unitary or programmed into the digitally programmable controller of
one-piece assembly. The blank 10 has a conventional form the machine. The entire semispherical ball end of the mill 22
Specifically configured for milling a corresponding a gas has Suitable cutting teeth thereon, shown Schematically, and
turbine engine fan or compressor blisk 16 which includes a 45 specifically includes a convex bottom portion 32 which
plurality of circumferentially spaced apart rotor blades 18 extends diametrically to a perimeter or side 34 of the mill 22
extending radially outwardly from the hub 12 which defines which is also capable of cutting.
the finished rotor disk which integrally Supports the Several During operation, the mill 22 is rotated for cutting the
blades 18 thereon. groove 26 with preferably only the mill bottom 32. The
Each blade 18 has a conventional configuration including 50 pocket Sidewall 28 is independently cut by using preferably
a generally concave preSSure Side and a generally convex only the mill Side 34 at its tangency.
Suction Side which extend from root to tip and between As initially shown in FIG. 2, the milling machine is
corresponding leading and trailing edges. Each blade has a Suitably programmed for feeding the rotating mill 22 in
Suitable airfoil configuration which typically twists about a plurality of alternating passes disposed generally in the axial
corresponding radial axis extending therethrough from the 55 direction for cutting a corresponding plurality of the grooves
root to the tip of the blade, with varying taper or change in 26 adjoining each other at bottom cusps 36 having a com
chord length therebetween. The camber of each blade also mon level to widen the pocket 30 between a pair of opposite
typically varies from the root to tip, with the resulting airfoil or circumferentially Spaced apart ones of the Sidewalls 28.
having a relatively complex 3-D contour requiring Suitably After the grooves 26 at one level are milled, the two
Smooth Surface finish Over the pressure and Suction sides 60 sidewalls 28 are then cut in turn with corresponding sides 34
thereof for maximizing aerodynamic efficiency. of the mill 22.
The blank 10 is milled or machined in a conventional In this way, the mill bottom 32 is used for cutting the
multiaxis milling machine 20 specifically configured for Several grooves 26 to a Suitably rough tolerance of plus and
rotating a cutting tool in the preferred form of a conventional minus a few mils and with a suitable excess side material 38
ball end mill 22 for point milling the blank 10. The blank is 65 relative to the required finish side of the respective blades
mounted in the machine 20 relative to the mill 22 typically 18. The pocket sidewall 28 may then be finish cut using the
with five degrees or axes of movement for following com mill side 34 to a suitable finish tolerance significantly less
 6,077,002
S 6
than the rough tolerance and down to about 0.8 mils (0.02 ing groove level. This allows a finish cut on the side of the
mm) for example. end mill at the ball tangency using a portion of the end mill
Although the Same mill 22 may be used in a first pass to reserved Solely for finish machining, whereas the bottom of
cut a Single groove 26 and then fed again over that groove the end mill is reserved Solely for rough machining.
to use the mill side 34 to finish machine the sidewall 28, it This process of stepping down the pocket 30 while
is preferred to cut the several grooves 26 for initially alternately roughing and finishing the bottom of the pocket
widening the pocket 30 in multiple rough machining radial 30 and the sidewalls 28 effects a more accurate airfoil shape
levels or steps followed in turn by finish machining the two since the blade 18 being formed is constantly supported by
Sidewalls 28 using the same mill 22, and then alternately solid material directly below the area where the finish cut on
repeating the groove and Sidewall cutting to deepen the the Sidewall is being made. This Stepping process proceeds
pocket 30 to its final and full depth in the perimeter of the until the entire pocket is finished to the platform by rough
blank. machining the pocket depth in increments and alternately
This preferred embodiment is illustrated in more detail in finish machining the pockets sidewalls 28 in turn. The
FIG. 3 wherein three circumferentially adjoining grooves 26 resulting pocket 30 will have the convex suction side of one
are initially formed axially across the perimeter of the blank 15 blade 18 and the concave pressure Side of an adjacent blade
10 to start the formation of single one of the pockets 30. The both to finished tolerance. The blank is then indexed to the
mill 22 is fed transversely across the perimeter of the blank next pocket and the proceSS is repeated preferably with a
in three exemplary passes as illustrated in FIG. 2 to form a new end mill 22 to avoid exceSS wear of the already used
center groove, a left groove, and a right groove in turn. mill.
The mill 22 may have an exemplary outer diameter 2R of In the preferred embodiment illustrated in FIG. 3, each of
about 500 mils (12.7mm), with the mill being positioned for the sidewalls 28 is side cut in a plurality of sub-steps or
using only the mill bottom 32 for forming the grooves 26. In sub-levels spaced radially above the level of the last cut
this way, the radial cutting depth of the mill is Selected to cut groove 26. For example, the mill 22 may be raised from
a groove 26 in each pass Substantially shorter in depth than level 7 to level 5 and then fed along the path of the
the radius R of the mill. For example, the radial cutting depth underlying groove 26 to machine the radially outermost
25 portion of the sidewall 28 to its finished dimension, for
may be about 50 mils (1.27 mm) which uses only one fifth
of the available cutting radius of the mill. example. The mill 22 may then be lowered a fraction of the
The mill is then repeatedly fed across the blank in full rough cutting level and again fed along the correspond
multiple transverse passes and multiple radial Steps or ing groove 26 for machining an additional radially inner
levels, with the first seven levels 1-7 being shown in partial portion of the sidewall 28.
phantom in FIG. 3. The seven radial levels each has a radial In the exemplary embodiment illustrated in FIG. 3, the
depth of about one fifth the cutting depth of the mill 22 end mill 22 is fed in four sub-levels designated 5,5a, 5b, and
which is sufficient to initially form the radially outermost 6 for side cutting the sidewall 28 to its finished dimension
portion of the incipient Sidewalls 28. down to the penultimate groove at level 6 to maintain a
After milling the seventh level, the mill bottom 32 is back clearance between the end mill 22 and the last cut groove 26
Stepped radially outwardly from a respective one of the 35 at level 7. Since the mill side 34 is also arcuate, Small side
grooves 26 adjacent either Sidewall 28 prior to cutting that cusps are also formed along the Sidewall 28 in each side
Sidewall. In this way, a finite gap is provided between the cutting pass. By using the multiple Sub-level passes, the
mill bottom 32 and the underlying previously cut groove 26. resulting Side cusps are Substantially removed resulting in a
The same or common mill 22 may then be fed along the path substantially smooth sidewall 28 for the finished blade 18.
of the underlying groove 26 near one of the sidewalls 28 for 40 AS shown in FIG. 1, the Step milling proceSS is initially
finish milling that sidewall to a suitable side-depth for used for step milling a full-depth, complete first pocket 30
achieving a suitable finished surface of the blade 18. Then in the perimeter of the blank 10, with the blank then being
the other sidewall 28 is similarly side-milled to finish circumferentially indexed to the next adjacent Second pocket
dimension. 30 which is then step milled in an identical manner to mill
The same mill 22 is then alternately used to continue the 45 a freestanding airfoil blade 18 in the form of a cantilever
Step milling downwardly for cutting the groove 26 with the extending radially outwardly from the hub 12 of the blank.
mill bottom 32 and then cutting the sidewalls 28 with the In the preferred embodiment, a first ball end mill 22 is
mill side 34. As shown in FIG. 3, the mill 22 is slightly used to step mill the entire first pocket 30 until its two
inclined from the radial axis for using its side 34 for side sidewalls 28 are finish machined. Then, a different second
milling one of the sidewalls 28, and is then repositioned with 50 ball end mill 22 of identical configuration is used to Step mill
an opposite inclination adjacent the opposite Sidewall 28 for the second pocket 30 completely to finish the two sidewalls
Side milling that Sidewall. 28 thereof.
In this way, the individual pockets 30 may be step milled Accordingly, it is preferred to use a plurality of different
in Small depth increments corresponding with each of the ball end mills of identical configuration to Step mill in turn
initial levels 1-7 and as many additional levels, i.e. level 8 55
a corresponding plurality of the pockets 30 to produce a
et. Seq., as required to reach the final depth of the pocket at plurality of the blisk airfoil blades 18 each in the form of a
the platform. Such partial depth milling allows very high freestanding cantilever having varying twist and taper from
rotary Speeds of the mill 22 and correspondingly high feed root to tip thereof to define the resulting blisk 16 illustrated
rates Substantially greater than those possible in conven in FIG. 1.
tional milling where a ball end mill is typically plunged Since the mill 22 necessarily wears during cutting, it is
radially to its full-radius cutting depth for maximizing 60
desirable to use the same mill for both rough and finish
material removal along all available cutting Surfaces of the milling in each pocket without change, if possible, to
mill. prevent the formation of a discontinuous cusp which would
In accordance with the invention, as each new level of otherwise occur upon eXchange of a new mill for a used mill
material is removed, a Small amount of exceSS Side material mid-pocket. The Single, Same mill 22 uses its different
38 is left on each side of the corresponding blades 18 being 65 portions for Separately machining the Successive grooves 26
formed. The side machining of the sidewalls 28 is preferably and the developing Sidewalls 28 to maximize cutting effi
a finish cut made preferably just above the previous rough ciency. The mill bottom 32 uses only a small portion of the
 6,077,002
7 8
entire mill for rough machining the corresponding grooves While there have been described herein what are consid
26, with the mill sides 34 being used for independently ered to be preferred and exemplary embodiments of the
sidemilling the sidewalls 28. present invention, other modifications of the invention shall
In both cases, only respective portions of the mill 22 are be apparent to those skilled in the art from the teachings
being used which therefore allows the mill to be operated at herein, and it is, therefore, desired to be Secured in the
a Substantially higher rotary Speed than a conventional full appended claims all Such modifications as fall within the
depth cutting ball end mill, and with a Substantially greater true Spirit and Scope of the invention. For example, the Step
feedrate as well. Since leSS material is being removed in milling process may be used on any other type of
each pass of the mill compared with the full depth cutting in component, besides blisks, which require rough and finish
the conventional process, the mill develops less cutting machining in Steps. And, other shapes of end mills may also
loads and improves tool life. be used.
Furthermore, since the finish sidemilling of the sidewalls Accordingly, what is desired to be Secured by Letters
28 is alternately effected after rough milling a corresponding Patent of the United States is the invention as defined and
underlying groove 26, the Sidewall 28 is rigidly Supported differentiated in the following claims in which
with little if any circumferential flexibility as found in the I claim:
freestanding conventional process. As a result, the finish 15
1. A method of milling a blank with a rotating mill
milled blades 18 can be made with suitably smaller manu compriSIng:
facturing tolerances and with a more accurate nominal cutting a groove having a bottom to partially expose a
dimension, and with greater accuracy from blade-to-blade.
This effectively eliminates the problem of blade-to-blade Sidewall in Said blank by feeding Said rotating mill
manufacturing variation found in the conventional proceSS acroSS Said blank,
which could cause unacceptable unbalance of the machined cutting Said Sidewall by feeding Said mill along Said
blisk. groove; and
Since it is desired to have relatively small blending radii alternately repeating Said groove and Sidewall cutting to
between the roots of the several blades 18 and the corre Step mill Said groove deeper in Said blank and form a
sponding platforms 24, a Subsequent milling operation may 25 pocket along which said Sidewall extends.
be effected using a smaller diameter ball end mill for finish 2. A method according to claim 1 further comprising:
machining the individual platforms 24 in a conventional cutting Said groove with a bottom of Said rotating mill;
C.
and
Accordingly, a Single type of ball end mill 22 is used for
both rough machining the grooves 26 in the pockets 30 as cutting Said Sidewall with a side of Said rotating mill.
well as finish machining the sidewalls 28 to form the 3. A method according to claim 2 further comprising:
corresponding finished blades 18. A single ball end mill 22 back Stepping Said mill bottom away from Said groove
may therefore be used to completely form an individual prior to cutting Said Sidewall; and
pocket 30 whereas the conventional process required three using a common mill for alternately cutting Said groove
ball end mills to Separately rough, Semi-finish, and finish the 35
with said mill bottom and said sidewall with said mill
pockets defining the corresponding blades. Side.
In addition to requiring few ball end mill changes from 4. A method according to claim 3 further comprising:
pocket to pocket, the total number of ball end mills required cutting a plurality of Said grooves adjoining each other at
for completely machining the entire blisk is about half the a common level to widen Said pocket between a pair of
total number of ball end mills used in the conventional
process. And a Substantial reduction in the number of 40 Said Sidewalls, and
individual cuts or passes is also achieved in accordance with cutting both of said sidewalls in turn with said mill side.
the invention. 5. A method according to claim 3 further comprising
Furthermore, the collective advantages of using a single cutting Said Sidewall in a plurality of Sub-Steps Spaced above
end mill for both roughing and finishing each pocket 30 Said groove.
result in a Substantial reduction in overall time for producing 45 6. A method according to claim 3 further comprising:
the complete blisk 16, roughly a 50% reduction in total time. Step milling a first pocket in Said blank, and
AS a result, the finished blisk 16 Step milled in accordance Step milling a Second pocket in Said blank Spaced from
with the present invention includes a plurality of blades 16 Said first pocket to mill a cantilever extending out
extending radially outwardly from the common hub 12 with wardly from said blank.
improved accuracy and finish as compared with a conven 50 7. A method according to claim 6 further comprising:
tionally point milled blisk. The 3-D contour of the individual using a first mill to Step mill Said first pocket; and
blades is more precise from blade-to-blade and has a dis using a different Second mill to Step mill Said Second
tinctly different and Substantially Smoother Surface contour pocket.
achieved with a Substantial reduction in number of cutting 8. A method according to claim 7 further comprising using
passes. The improved blisk 16 itself therefore has aerody 55 a plurality of different mills to step mill in turn a plurality of
namic and Structural advantages over the conventionally Said pockets to produce a plurality of Said cantilevers in the
point milled blisk. form of airfoil blades having varying twist and taper from
The Step milling proceSS Significantly decreaseS process root to tip thereof.
ing time Since there are fewer cuts required to rough and 9. A method according to claim 7 wherein:
finish the blisk, and those cuts can be done at a significantly 60 Said groove cutting has a rough tolerance; and
faster feedrate and rotary Speed because of the shallow depth
of each cut. This, in turn, reduces cutting forces for reducing Said Sidewall cutting has a finish tolerance less than Said
wear and tear on the ball end mills as well as on the milling rough tolerance.
machine 20 itself. The Step milling proceSS is now focused 10. A blisk (16) step milled by the process of claim 7 to
on milling an accurately sized pocket 30 instead of milling produce a plurality of blades extending radially outwardly
around individual blades, resulting in a more accurate air 65 from a common hub.
flowpath through the pocket and between the adjacent
blades.