Process and apparatus for producing service blades

A process for machining a blank from all directions with a machine tool, the machining from all directions being based on a three-dimensional template, wherein the machine tool includes a machine bench having an A-axis, the process comprising:

• automatically measuring three-dimensional spatial form and optionally surface finish of the three-dimensional template, and saving associated measurement data, the three-dimensional template being restrained in clamped position during a portion of the measuring at ends thereof in the A-axis, and the three-dimensional template being restrained at a central region thereof during another portion of the measuring for tip and root regions of the three-dimensional template;
• using the measurement data, machining clamping jaws for clamping the blank in a first region, said clamping jaws being configured and dimensioned particularly for clamping the first region;
• holding the blank with at least one first clamping adapter while preparing the first region into final, ready to use partial form with the machine tool using said measurement data for numerical control;
• and
• holding the blank with at least one second clamping adapter having the clamping jaws, the blank being held in the first region that was already prepared, and preparing a remaining region of the blank into final, ready to use overall form with the same machine tool using said measurement data for numerical control.

A process for machining a blank from all directions with a single machine tool, the machining from all directions being based on a three-dimensional template, wherein the three-dimensional template is a blade that is a moving blade or stationary blade that is to be replaced in a turbine and the blade has a length less than 200 mm, and wherein the machine tool includes a machine bench having an A-axis and a W-axis, the process comprising:

• automatically measuring three-dimensional spatial form and optionally surface finish of the three-dimensional template in the machine tool, and saving associated measurement data, the three-dimensional template being restrained in clamped position during a portion of the measuring at ends thereof in the A-axis, and the three-dimensional template being restrained at a central region thereof during another portion of the measuring for tip and root regions of the three-dimensional template;
• holding the blank with at least one first clamping adapter while preparing a first region into final, ready to use partial form with the machine tool using said measurement data for numerical control, wherein while preparing the first region, the blank is grasped by clamping jaws of the at least one first clamping adapter in the W-axis of the machine bench;
• and
• holding the blank with at least one second clamping adapter in the first region that was already prepared, and preparing a remaining region of the blank into final, ready to use overall form with the same machine tool using said measurement data for numerical control, wherein while preparing the remaining region, the blank is grasped in the A-axis of the machine bench, the blank being grasped proximate at least one end thereof that has already been prepared and being grasped and optionally fixed at another end thereof by means of a movable tailstock.