TITANIUM MACHINING
were limited to fi nish operations, but when AM eliminates the roughing, ultrasonic can be applied to most of the remaining milling ops.”
High-Torque Machine Tools
While AM has a place at the table, conventional machining is still the pre- dominant Ti strategy. “While AM will help us reach the goal of near-net shapes, it will be some time before the process is perfected, and we continue to improve high-torque solutions,” said Jeff Wallace, engineering manager for DMG Mori USA. Makino has several machines specifi cally for titanium, including the T4, T2 and most recently the T1. Brian List noted that his company’s 1000 Nm high-torque spindles, with HSK 125 or HSK 100 adapters supported by large cast- ing structures, can drive cutters smoothly through titanium.
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“Machining in the horizontal position with high-pressure, high-volume coolant ensures that chips are cleared and cut- ters are cool. Compact fi ve-axis construction allows roughing operations that interpolate offset from the fi nal fi nished shape of the part.” This reduces or eliminates semi-fi nish passes and increases tool life and fi nishing speed by eliminating steps and extra material left by traditional roughing. Mazak’s Super High-Torque Mega 8800, an 800-mm HMC, is designed for titanium and other tough-to-machine materials. Also, the Mazak HCN 6800, a 630-mm HMC, is available with a hard-metal package that includes a high- torque spindle, vibration-dampening bed casting and an extra heavy-duty column. “We also can include additional trucks [roller bearing packs],” said Kerscher. “Instead of four trucks, two on each side of the column, we use six trucks to add stability.” One issue is that Ti shops may want to cut other materi- als, such as aluminum, at higher speeds. Also, they may want to rough Ti on four-axis machines, then fi nish cut on fi ve-axis machines. “We can facilitate that with our Palletech automated pallet delivery system, which allows combinations of horizontal machines and fi ve-axis machines within the same production cell,” said Kerscher. Haas Automation’s Terryberry agreed that large, high-
torque machines aren’t always needed for titanium machining. “It all depends on part size,” he said. “If you are machining large parts using end mills more than 1" [25.4 mm] in diameter and need a high MRR [material removal rate], you need a high- torque, 50-taper machine, such as our VF-6 through VF-12 VMCs, for slot cutting and other operations. But if you are do- ing detailed parts with small inside corners using end mills less than 1" in diameter, you don’t need extra torque.
62
AdvancedManufacturing.org | February 2017
Photo courtesy Heartland Enterprises
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