Kaplan blades

 Manganese-nickel steel or chromium-nickel steel

Kaplan turbines are water turbines against which water flows in an axial direction and which have an efficiency of 80–95%. They were developed by Viktor Kaplan, based on the Francis turbine, and are particularly suitable for large hydraulic power stations located on calm bodies of water.

Their adjustable rotor is similar to a ship's propeller. Walter offers highly efficient machining tools and complementary machining processes for manufacturing these components


Roughing outer diameters on the blade flange

Solution:

Walter Xtra·tec® F4238 porcupine milling cutter

  • ► Large range of cutting depths can be covered
  • ► Extremely soft-cutting geometry
  • ► High material removal rates

Finishing mating faces on the flange

Solution:

Walter F2010 adjustable face milling cutter

  • ► Adjustable runout
  • ► Exchangeable cartridges, only one basic body
  • ► Tiger·tec® Silver cutting tool materials for a long tool life and high process reliability

Pre-drilling connecting holes on the blade flange

Solution:

Walter Xtra·tec® B4213 insert drill

  • ► Force-fit insert clamping
  • ► Ideal insert position ensures forces are balanced during the machining process
  • ► Optimised chip space and robust tool body
  • ► Hard-nickel-plated surface provides protection against wear and corrosion
  • ► Wiper edge inserts at periphery

Roughing turbine blades

Solution:

F2334R round insert milling cutter

  • ►  Optimised insert seat design
  • ►  Reinforced tool adaptor
  • ►  Direct coolant supply to the cutting edge
  • ►  Four cutting edges per indexable insert
  • ►  Insert sizes: RO.X 10T3.. or RO.X.1204..