Precision Machining of Runner Components for Small-Scale Turbine Simulation Systems

Sector

Energy Engineering – Custom Machining of Mini Turbine Components Based on Specialized Technical Drawings

Solutions

Precision machining of a 15-blade Runner component with complex twisted geometry, integrated threaded holes, and a closed spiral profile as per advanced engineering design

Client Feedback

“We highly appreciate IDEA’s ability to accurately machine twisted geometry and maintain tight tolerances. The Runner component fully met our aerodynamic simulation requirements.”

複雑形状ランナーの精密部品加工｜5軸CNC 加工によるねじれ羽根の高精度製作事例, chi tiết runner

Project Overview

The machined part in this project was a Runner component with 15 twisted blades, developed for a client specializing in R&D of compact turbines used in educational, experimental, and technology demonstration applications.

This Runner is part of a turbine flow simulation device, requiring excellent blade uniformity, precise theoretical twist angles, and smooth surfaces to optimize airflow behavior.

Challenges

Complex 3D twisted geometry, requiring uniform machining across all 15 blades based on standardized coordinates.
Tight tolerance requirements for blade gap and tilt angle (< ±0.05 mm).
Multi-step process involving turning, profile milling, drilling, tapping, and fine grinding.
Material: hardened alloy, prone to thermal deformation during machining.

Solution & Implementation

1. CAM Programming and Digital Simulation

Used Siemens NX software for advanced 5-axis CAM programming and digital twin simulation.
Divided the Runner blades into coordinate groups to ensure consistency and accuracy on 5-axis CNC machines.

2. High-Precision CNC Machining

Machined the entire Runner component from a solid round billet using a 5-axis Mazak CNC machine.
Applied high-pressure coolant during cutting to maintain surface hardness and minimize thermal distortion.

3. Finishing and Quality Control

Threaded holes were drilled and tapped with concentric alignment, verified using dial indicators.
Final hand-polishing ensured smooth airflow along the blade surfaces.

Results

Successfully machined the 15-blade twisted Runner component with dimensional uniformity within ±0.02 mm.
Verified twist angles across all blades matched original CFD (computational fluid dynamics) design specifications.
Project completed in just 9 days, 3 days ahead of schedule.
The client was highly satisfied and proposed further collaboration for similar clean energy research models.