machine structures that can affect accuracy are enclosed and provided with engineered heated and cooled conditioned air and coolant. Te XS bridge mill can have X-axis travels of 22 m or more for machining lay-up molds and tools that are used to fabricate extremely large composite parts for the outer skins of aircraſt like the Airbus A350 and Boeing 787. Another machine that uses a similar method of thermal
constancy is the Parpas OMV/Formula. Two Formula machines have been in service at Lockheed
Martin Fort Worth for a turnkey solution milling the F-35 fighter jet center section fuselage. Tat project employed both the thermal management system mentioned above for the XS, in addition to an automated cell with temp control and air filtering. “Te XS machine is an overhead gantry machine that has
the ability to encapsulate the entire machine without putting it into a controlled environment, including column sides, the bridge which is the cross rail, the ram and ram saddle with the exception of the guideways of the ram [the vertical axis],” said Tom Hagey, operations manager. “Te ram protrudes down to the table of the machine with the head. Boxways that are hardened and ground and exposed in ambient temperatures are gundrilled out and refrigerated coolant is passed through,” said Hagey.
hardenable titaniums, we don’t think of titanium as being as difficult to machine as in the past,” said Mulvey. “Because all of these materials have low machinability
ratings, we strive for predictability in tool life. We provide a quality tool so that the customer knows how oſten he has to change the insert on a consistent basis. It helps that most ma- chines today have a tool management system that will tell the operator when it’s time to change the insert so that valuable time isn’t lost in production,” said Mulvey. “A recent example is one customer who is machining a component for the aerospace industry from premium nitriding steel. We recom- mended a coating that is running with phenomenal success. Previously, CBN was used and the process had to be stopped mid-cycle to allow the material to cool. Our free cutting geometry in combination with the coating allowed non-stop production. Tis custom solution reduced the scrap rate and improved the overall component quality.”
Toolholding Technologies Ensure Quality Results Haimer USA (Villa Park, IL) offers three toolholding
technologies that are designed to produce quality machining results, especially in high-speed machining applications. “Te first is our balancing equipment that is designed to balance tooling assemblies before they go into the machine,” said
“Balanced tooling produces excellent surface finishes, extends tool life, and prevents possible damage to the spindle.”
“AIP Aerospace Tooling Group has ordered four of our ma-
chines, one for their Odyssey division in Michigan; the other three for their Coast Composites Irvine, CA facility. Tey’ll be used to produce the tools for building composite parts for the Boeing 787 and Airbus A350. One of the machines, a dual gantry model has travel of 59 × 15' [18 × 4.5 m],” said Hagey.
Tool Selection Leads to Predictability According to Ed Mulvey, technical support applications
engineer, Horn USA (Franklin, TN), multitasking machin- ing using tools like Horn’s spline milling and gear milling tools can complete a gear or a hub with a spline on it in one setup on the latest multitasking machines. “Te real benefit for the user is that quality of the part is ensured as handling is minimized. Our tools are especially well suited to meeting the requirements of tough grooving that are required on aero- space parts. All of our tools are diameter specific for the bore size and depth of groove,” said Mulvey. “Te secret of effective machining is in getting the best
combination of substrate, cutting edge and coating, especially for applications involving difficult-to-machine materials, like Inconel, titanium, high-end stainless, precipitation stain- less, cobalt alloys and Stellite. Except for some of the newer
Brendt Holden, president. “A tooling assembly includes the toolholder with the cutting tool and all accessories such as pull-studs, nuts, collets, face-mill cutters, inserts, etc. Balanc- ing the complete assembly allows the machine to run fast, es- pecially in aluminum machining, without creating vibration at the cutting edge. Balanced tooling produces excellent surface finishes, extends tool life, and prevents possible damage to the spindle,” said Holden. Te second technology is Cool Flash which is integrated
into Haimer’s Power Shrink chuck with Cool Jet. “Cool Flash overcomes the tendency of coolant to flare out away from the cutting zone in high-speed applications. It is especially effective in aluminum structural machining where a lot of chips are created or in deep milling applications on vanes where it’s difficult to remove chips in jet engine machining,” said Holden. “Cool Flash allows the coolant to come around the cutting tool where it is redirected back to the shank of the cutting tool where it follows the shank of the tool with a high pressure to cutting zone.” Te third technology is the Safe Lock which is designed to prevent tools, principally high helix end mills, from being pulled out of the holder in high-speed structural aluminum machining or in titanium roughing applications. ✈
Aerospace & Defense Manufacturing 2014 85
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