Transformation of gas turbine engine shaft production in Perm

JSC UEC-Perm Engines is implementing the GTE shafts (“Long shafts”) project as part of the comprehensive program to modernize the production of the United Engine Corporation of Rostec. The project provides for the creation of the closed-loop production chain of shafts in the new center of specialization, equipped with modern high-tech equipment that will allow reducing the time for processing parts and improving the quality of products.

The center of specialization will be located at two production sites. The first one is the shaft machining production cell. The majority of the machines has already been received; the installation of the unique robotic cell on the basis of two machining centers was completed in August. Its specific feature is that all auxiliary processes that have previously been performed by the operator now will be carried out in an automatic mode. Once the cell capable to operate round the clock is commissioned, it will reduce significantly the shaft machining cycle and the need for highly qualified specialists and minimize the number of defects related to human factor.

In addition the GTE shaft specialization center is also integrating a modern information system which will move production planning to a new level.

“It is a large-scale and prestigious project for us: so far no enterprise in Russia has introduced a complex of automated equipment for the production of such large-sized parts as shafts. The ultimate throughput is 1,500 pieces per year. The plant plans to reach this capacity by 2030. JSC UEC-Perm Engines produces about 300 shafts per year now. The shafts are required not only for production engines, but also for prospective engines PD-14, PD-8, PD-35, which are made in a wide cooperation of UEC enterprises,” says Executive director of JSC UEC-Perm Engines Sergey Kharin.

The purpose of creating  a new production cell is to accumulate a full shaft production cycle at one place. It will accommodate a maximum number of operations: from drilling of blanks, roughing, overall machining up to heat treatment, painting, polishing, balancing, automated inspection and packing of the products. The testing of production process in an automated mode begins in September – first with the test workpieces, then with real shafts. The equipment will be finally put into commercial operation in October this year.

The second production site is heat treatment cell for the shafts up to 3 meters long. Currently the site is under reconstruction, the installation of the equipment is scheduled for the second quarter of 2022.

In total, by the end of the first quarter of 2022, 48 pieces of the equipment will be delivered in the framework of the project, including automated warehouse complexes, automatic shot-peening system, automatic polishing system, and an automatic painting system. The unique machines will be maintained by highly qualified specialists with a vast experience in similar equipment.