AEROSPACE MACHINING
virtual applications to detect cutting problems and prevent time-consuming and costly crashes.
The Multus B750 technologies make it possible to limit operator intervention and work handling. But Northstar went a step further working closely with an Okuma application engineer to fi ne-tune cutting processes. They discovered by changing up the order a part is cut, distortion is minimized resulting in improved process effi ciency. The collaboration worked well because each member of the team brought a unique perspective and knowledge to the project, allowing process change and development that otherwise, would not have occurred.
Partners in THINC technologies include a Renishaw probe that is used for in-process gaging, which allows the machine to check the part itself without operator intervention. CAD/ CAM software programming by ESPRIT provides part-cutting solutions that incorporate the gaging into the post processor G-code. Tool Monitor Adaptive Control (TMAC) from Caron Engineering monitors electric current load to the turning and
milling spindle and will stop the machine if loads exceed the established values. This also has an adaptive feature that increases or decreases cutting feed rates if loads are within a safe cutting range. A high-pressure coolant system from MP Systems provides better coolant fl ow to the cutting tool and helps extend tool life. Following installation of the Multus B750, Northstar added another Okuma machine tool, an LB35III horizontal lathe.
Cryogenic Machining Cuts F-35 Part Cost by 30% Cooling titanium while cutting is critical, so much so that
high fl ow rate through-the-tool fl ood cooling is the most common way of achieving desired cooling and lubricating results. Coolant volumes run as high as 50 gpm (189 L/min) through the spindle at 1500 psi (10 MPa) because of the volume of chips that have to be evacuated. Enter cryogenic machining. Lockheed Martin acquired an Okuma MA-600HII horizontal machining center equipped with patented cryogenic machining systems from 5ME LLC (War- ren, MI) to perform roughing and fi nishing operations on large titanium airframe components for the F-35 Joint Strike Fighter program. Test cuts performed on 6 Al-4V titanium produced a 52% increase in cutting speeds (21 hours with 5ME cryo- genics compared with 44 hours for coolant), while maintain- ing equal cutter consumption. The tests, using a 5ME solid carbide cryogenic end mill, also produced improved surface integrity and part quality, as well as reduced white layer. Ac- cording to Lockheed, cryogenic technology will help lower the cost of large titanium parts by an estimated 30%.
“The tests we conducted with Lockheed demonstrate the true business advantages of using cryogenic machining for tough-to-cut materials, such as titanium.”
“The tests we conducted with Lockheed demonstrate the true business advantages of using cryogenic machin- ing for tough-to-cut materials, such as titanium” said Pete Tecos, 5ME executive vice president marketing and product strategy. “This has a signifi cant impact on cost savings for initiatives like the F-35 program, not only in increased cutting speeds, but also through lower energy consumption, im- proved worker safety, and the elimination of the infrastructure and disposal required with fl ood coolants.”
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AdvancedManufacturing.org | February 2016
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