MAX-PAC Brochure Concepts NREC Web

CAM Software
The Experts in Turbomachinery
MAX-PAC™
Computer-Aided Manufacturing Software
• Engineering • Software • Manufacturing • Training

Concepts NREC
For over 60 years, Concepts NREC has been partnering with the world’s leading OEMs to improve the
performance and manufacturability of turbomachines. We are the only company in the world whose in-
house capabilities span the entire process — from conceptual design through manufacturing, testing, and
installation. This unique perspective creates powerful synergies that drive innovation across our entire of-
fering. Our clients benefit from having a trusted partner who can see the big picture and provide valuable
insights that save them time and money.
We are ISO 9001:2015 and AS9100:2016 certified and committed to providing our customers with prod-
ucts and services that meet international quality standards.
Advancing the State of the Art in Turbomachinery

Concepts NREC maintains a robust in-house research and development program. We hold over 70 pat-
ents worldwide, with numerous patents pending. Concepts NREC is also the leader of the global Advanced
Centrifugal Pump and Compressor Consortium for Diffuser and Volute Design, an internationally sponsored
research venture dedicated to advancing diffuser and volute design.
We push past what has been done to explore what can be done. Concepts NREC has the vision to
create great designs and a hard-earned reputation for delivering them.
Engineering Software
• Design Optimization • 3D CFD Flow Analysis

• Design Services • 5-Axis CNC Machining
• Engineering Audits • Design Optimization
• Equipment Rerates and • FEA Stress and Vibration Analysis
Upgrades • Integrated Preliminary and
• Feasibility Studies Detailed Design Solutions
• Laboratory Testing • Rotor Dynamics
•
Manufacturing Training
• Balance Testing • Customized Training
• CMM Inspection • Design Software Workshops
• Component Assembly • Free Webinar Series
• Concurrent Engineering/Manufacturing • Manufacturing Software Workshops
• Modal Analysis • Professional Development Courses
• Prototypes • Textbooks
• Reverse Engineering
• Short or Long Production Runs
Industry-Leading Software Suite
The Agile Engineering Design System® is a complementary suite of programs for Computer-
Aided Engineering (CAE) and Computer-Aided Manufacturing (CAM). The seamlessly integrated
CAE modules cover the entire design process — from preliminary sizing through fluid dynamics and
mechanical stress and vibration analysis. Final designs can be easily transferred to our CAM software,
MAX-PAC, to create efficient 5-axis machining strategies.
MAX-PAC — Specialized for Turbomachinery

Based on decades of experience, and incorporating several patented
methodologies, MAX-PAC is recognized as the best software for 5-axis
milling of turbomachinery impellers, blisks, and rotors. MAX-PAC is used
worldwide by turbomachinery manufacturers, job shops, and 5-axis
machine-tool manufacturers who are passionate about producing the
highest quality parts.
Machine Parts Better, Faster, Cheaper

Manufacturing turbomachinery components is often a challenge, due
to hard materials, thin blades, tight tolerances, smooth surface-finish requirements, or difficult tool access.
MAX-PAC was built from the ground up to address these challenges and enables users to produce
high-quality components in less time and at a lower cost.
Compared to other general CAM tools, MAX-PAC is faster to learn, easier to use, and requires less
programming and machining time. MAX-PAC offers a choice of cutting strategies to meet specific milling
requirements.
MAX-PAC Advantages
• Specialized for turbomachinery production
• Easy and fast to learn with intuitive user interface
• Supports a broad selection of tool geometries
• Faster machining times with optimized cutting strategies
• Smooth 5-axis toolpaths for high-speed milling
• Collision-free toolpaths for difficult geometries
• Superior surface finish and tight tolerances using a patented flank- or point-milling approach
• Produces high-quality parts that don’t require hand finishing or other reworking
MAX-PAC Milling Modules
MAX-PAC offers several add-on modules, each focused on a different milling strategy. Clients can
purchase any combination of these modules to meet their specific machining requirements.
MAX-5™ for Flank Milling

Flank milling efficiently finishes the entire blade
surface with one pass using the side of the cutter.
MAX-5 creates 5-axis CNC machining instructions
for flank milling of ruled-surface turbomachinery
components. Typical applications include parts
for centrifugal compressors, pumps, inducers,
fans, turbochargers, stators, radial-inflow turbines,
expanders, and torque converters.
With MAX-5’s patented algorithm, dramatic cost

savings can be realized using ruled-surface designs
and flank-milling. Compared to other CAM systems,
MAX-5 is often capable of generating flank milling
toolpaths with an 80% to 90% error reduction.
MAX-5 supports ruled blade surfaces with optional non-ruled edge constructions. It also includes options
for roughing, plunge milling, hub finish, flank-milled blade finish, leading edge, fillet finish, and tip milling.
MAX-AB™ for Point Milling

Point milling of turbomachinery components uses the tip of the tool to machine arbitrary (free-form) blade
surfaces. Typical applications include axial compressors and turbines, pumps, compressors, turbochargers,
radial-inflow turbines, and inducers.
MAX-AB creates smooth 5-axis machining in-

structions that are compatible with high-speed
milling applications. MAX-AB is generally applied
to the class of components that are designed with
arbitrary surfaces, but it can also be used with
a high-speed milling process for ruled-surface
components. MAX-AB is particularly suited to to-
day’s CFD-influenced blade shapes that can be
difficult or impossible to cut with other general CAM
systems.
MAX-AB includes advanced capabilities for rough-

ing, plunge milling, hub finish, point-milled blade
finish, leading edge, fillet finish, and tip milling. Both
spherical-shaped and barrel-shaped tool-tips are
supported.
MAX-SI™ for Integrally Shrouded Impellers
One-piece shrouded (enclosed) impellers provide
many advantages over parts produced as an
assembly of separate hub and shroud components
(or even individual blades). The advantages include
less raw material and fewer manufacturing process
steps. Also, integrally shrouded components avoid
heat distortion and have stronger shroud joints than
fabricated assemblies.
MAX-SI creates 5-axis CNC instructions for milling

integrally shrouded turbomachinery components
for expanders, pumps, compressors, and turbines.
It can also generate machining instructions for large
axial compressors and blisks, using a side-entry
machining approach.
MAX-SI includes strategies for pocket roughing, plunge milling, box passes for finish/semi finish, and flow-
direction finish milling.
MAX-SB™ for Single Blades

MAX-SB generates toolpaths for quickly machining
single blade parts with smooth 5-axis motion. It is
specifically designed for flat/torus cutters that are
more efficient than a ball tool. MAX-SB also pro-
vides optimized angles for the smallest cusps, to
avoid gouging in concave areas.
MAX-SB uses 5-axis milling for efficient material

removal, but 4.5- and 4-axis cutting is also possible.
Single blade parts are fixtured with the stacking axis
aligned with the machine rotary axis.
3+2 Roughing Module

The 3+2 Roughing Module enables the creation of 3-axis roughing toolpaths at an arbitrary angle with
planar roughing levels. It optimizes the toolpath to
provide a constant cutting load, making it suitable
for high-speed machining. Rounded corners and
helical inserts between levels are supported. Stock
awareness also cuts only the material remaining
from previous operations.
The 3+2 Roughing Module provides an extremely

useful roughing alternative for large impellers and/
or hard materials, and can be applied to impellers,
blisks, and shrouded wheels.
MAX-PAC Features
MAX-PAC and its add-on modules share these advanced features:
User-Friendly Interface
The MAX-PAC interface allows even the novice to become a power user. It
guides the programmer to enter machining operations and specify parameters
for each operation. Input values are checked for validity, and on-line help is
available. Inputs are stored and can be used for similar applications.
Geometric Modeling
MAX-PAC can be applied to a wide range of turbomachinery components,
including centrifugal and axial bladed parts. The software can scale components,
rotate coordinate systems, and create many turbomachinery-specific design
constructions as required. These can include leading- and trailing-edge shapes,
constant and variable-radius fillets, and blade thinning. Splitter blades are also
supported. The part model can be exported in IGES format ready for CAD systems.
Cutter Geometry
MAX-PAC can specify cutter shapes that include
cylindrical and conical ball end mills, flat mills,
corner-radius mills, plunge mills, barrel cutters, and
burr (lollipop) cutters. The cutter holder/spindle
geometry can also be specified for collision checking.
The tools are defined with graphical 2D and 3D
display. A master tool library can also be created to
easily import existing tool definitions to a new case.
Automatic Tool Selection

MAX-PAC can select cutter sizes from a cutter
catalog for each operation, or confirm user-specified cutters. The cutters are checked against specific
parameters, such as operation depth and stock offsets. To optimize material removal, the program selects
the largest cutter that will fit in the specified blade pocket.
Data Conversion
MAX-PAC can import many different tabular engineering data formats, such as camber line and thickness
definitions, as well as non-streamline data grids. An optional CAD Translator module is also available for
importing CAD files.
Multi-Axis Output
MAX-PAC generates continuous 5-axis toolpaths that are required for most turbomachinery components.
When the part geometry permits, 4.5-axis, 4-axis, and 3-axis toolpaths can also be generated.
Milling Strategies
MAX-PAC offers toolpath templates, derived from years of
experience and customer feedback. Depending on the licensed
module, strategies are available for roughing, hub finish, blade
finish, leading edge, variable fillet, tip chamfer, deburring, and
shrouded pocket milling. Programmers select the method, cut-
ter size, step-over specifications, and material stock, and then
MAX-PAC automatically generates the cutter paths. There is
no need to also construct complicated drive surfaces.
Tool Orientation
MAX-PAC includes a patented collision detection and avoidance module. This
ensures smooth, collision-free machining instructions. Tool orientation relative to
the path is controlled for favorable roughing and finishing conditions. MAX-PAC’s
algorithm allows larger cutters for more efficient milling, and it often can produce
a toolpath for difficult blade shapes that cannot be processed with general CAM
systems. Cutter orientations are also automatically calculated by the program, which
provides a major programming productivity improvement over other CAM systems.
Material Removal Simulation

MAX-PAC’s toolpath simulation includes material removal
mode that shows the remaining stock condition and details like
machining cusps. The simulation checks for collisions between
tool holders and the virtual milled model. The tool tip path can
be displayed, along with analysis modes, to display tool vectors,
drag/drill angles, and rotary axis reversals. The animation uses
a fixed-part reference or a patented fixed-cutter reference.
Machine Compatibility
Standard output from MAX-PAC contains APT GOTO
commands that are compatible with commercially available postprocessors. Direct postprocessors can
also be developed upon request and include custom commands for each user.
Integration with Concepts NREC’s AxCent® Blade Design Software

A key benefit for customers who design impellers, blisks, and single blades with AxCent is the seamless
link between our design and manufacturing software. With just a single button click, the entire geometry
can be transferred from AxCent to MAX-PAC. This enables designers using AxCent to quickly determine
manufacturing feasibility and reduce
the cost of each part. This unique, one-
click functionality eliminates the
time-consuming process of transferring
designs from a design system or CAD
model to CAM. It also removes the risk
of associated errors that can happen
during the manual transfer of geometry.
The Experts in Turbomachinery
London, UK
White River Junction, USA
Shanghai, China
Bangalore, India
Worldwide and regional headquarters. We also have sales offices and representatives strategically located
throughout the world to support our global clients.
We Offer Our Focus Concepts NREC

• Air Dynamometers Corporate Headquarters
• CAE Software
217 Billings Farm Road
• CAM Software • Compressors White River Junction, VT 05001
• Design Audits • Fans and Blowers
Phone: +1 802-296-2321
• In-house Laboratory Testing • Gas Turbines
Email: info@conceptsnrec.com
• Manufacturing Services • ORC Turbine Generators www.conceptsnrec.com
• Precision Prototypes • Pumps
• Research and Development • Steam Turbines
• Scoping Studies • Superchargers
• Specialized Products • Turbochargers
Agile Engineering Design System, AxCent, AXIAL, COMPAL, FANPAL, PUMPAL, RITAL, Pushbutton FEA, Pushbutton CFD, CTAADS, TurboOPT ll, MAX-5, MAX-SB, MAX-
AB, MAX-SI and MAX-PAC are registered trademarks or trademarks of Concepts NREC, LLC. Other company, product, or service names, including VERICUT, GasTurb and
Dyrobes, may be trademarks of their respective owners. © Concepts NREC, LLC. All rights reserved.

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CAM Software

The Experts in Turbomachinery

• Engineering • Software • Manufacturing • Training

Advancing the State of the Art in Turbomachinery

• Design Optimization • 3D CFD Flow Analysis

MAX-PAC — Specialized for Turbomachinery

Machine Parts Better, Faster, Cheaper

• Easy and fast to learn with intuitive user interface

• Supports a broad selection of tool geometries

• Faster machining times with optimized cutting strategies

• Smooth 5-axis toolpaths for high-speed milling

• Collision-free toolpaths for difficult geometries

MAX-5™ for Flank Milling

With MAX-5’s patented algorithm, dramatic cost

MAX-AB™ for Point Milling

MAX-AB creates smooth 5-axis machining in-

MAX-AB includes advanced capabilities for rough-

MAX-SI creates 5-axis CNC instructions for milling

MAX-SB™ for Single Blades

MAX-SB uses 5-axis milling for efficient material

3+2 Roughing Module

The 3+2 Roughing Module provides an extremely

Automatic Tool Selection

Material Removal Simulation

Integration with Concepts NREC’s AxCent® Blade Design Software

White River Junction, USA

We Offer Our Focus Concepts NREC

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