Case Study Mirage machines


willhartshorn Case Studies, Orbital MIlling Leave a Comment


A leading European manufacturer of wind turbines required the face of the composite rotor to be machined at 2.4m diameter. The rotor blade had composite structure with both steel and GRP. The flatness tolerance was to be within 0.20mm at 2.4m and machining time within 1 hour. Since its introduction we have now developed machines for 45m, 50m and recently 61m blades.


UK, Denmark, India, USA, Germany, Portugal


Mirage WP2500WP3500 with adapted base to mount on the 3 off moulded installation bolt holes within the blade GRP structure. A specifically developed power pack and trolley were also supplied to assist in providing the shortest floor – floor machining time possible. More recently a new fast mount hydraulic clamping system to further reduce setting time.


The machine is mounted using the special base to the 3 mounting points or through our patented hydraulic chuck allowing both the structure and machine to remain in it’s “free state” to get the best accuracy from the structure and machine possible. The high spots on the flange are then recorded and depth of cut set with the digital scale. The machine is fitted with a 125mm face mill and machining commences at 400 mm/min giving a rotation time of 20 mins. Floor to floor machining times of 30 minutes are now possible and they have been used in the production of over 10,000 blades.

Leave a Reply