CUTTING TOOLS
cycles with Softsynchro collet-type tap holders. Our KSN/ HD Softsynchro design features patented constructional separation of the transmission of torque and axial force which improves machining and thread quality while increas- ing tool life,” said Hatch.
Partner Knowledge Resolves Machining Conundrum Ken Bellinger, CET (Component Engineered Tooling)
manager, Seco Tools LLC (Troy, MI), said that knowledge from technology partners was instrumental in solving a production challenge for an older aerospace component from one of its customers. “The titanium part was challeng- ing because the prints were 20 years old. We found a 3D scanning company, scanned the part, built models around the print based on the original specs, and found that the features they were making weren’t necessarily on the prints. The workpiece was a milled part with a shaft that had to be turned and threaded. Our solution eliminated the need for the lathe and a whole series of secondary processes, cut the cycle time in half, and eliminated a manual drill- ing operation. The net result was the component became manageable and they could make money on a production run of 500 per year.”
“The investment that we’ve seen in heavy-duty machines has been tremendous for machining these metals.”
“The CET group acts as an engineering resource for our customers, drawing on the experience of 12 hubs around the world and meeting regularly to discuss common machin- ing projects encountered in the automotive, power genera- tion, medical device, and large equipment manufacturing industries. CET process engineers work with our knowledge partners including machine tool builders, workholding com- panies, gaging, and CAD/CAM systems to supply engineered tooling solutions. Our solutions can include inventory man- agement, training programs, engineering resources, custom tooling and design resources as well as providing training,” said Bellinger.
Solutions Include Standard, Special Tools as Needed “The challenge with machining titanium and Inconel is extending tool life and reducing cycle time as much as pos- sible,” said Yourik Gharibians, aerospace specialist, Walter
64
AdvancedManufacturing.org | January 2015
USA LLC (Waukesha, WI). “What I really see out there most of the time, people are not employing the tool in the right pa- rameter, not using the right tool. You need to know the mate- rial and choose the best geometries to machine it. About 60% of the business in aerospace is in specials, but we have a lot of standard inserts that are used in combination with special cutters. High-temperature materials don’t like to be pushed. They aren’t like steel or cast iron, so the geometry of the insert or the end mill has to be specific for that material and tools have to be sharper,” said Gharibians. “At first, it might be difficult to get customers to run more
aggressively with our new tools. With our geometries, we’re taking the heat off the part and tool and sending it out with the chips, so the part stays cold and the chips hot. In most cases in high-feed applications, they were using old-style cobalt end mills running at 3 ipm [76 mm/min]. When I give them my cutters and tell them they can run at 36 ipm [914 mm/min], they’re reluctant at first, until they get their first good machining results,” said Gharibians. Walter’s Proto-max Inox solid carbide tool is specifically designed to address work hardening of titanium and other high-temperature metals. It features a sharp cutting edge and a tough substrate with a thin coating that is appropriate for the titanium. It has a lot of lubrication qualities which helps the material flow, and it can handle the heat that’s gener- ated. The inserts have the same qualities as the Proto-max Inox, tough substrate, with a very sharp cutting edge and thin aluminum oxide coating applied with the PVD process. Applying the aluminum oxide with PVD process keeps the processing temperature lower which helps retain the integrity of the carbide and still retains the heat-resistant property and wear resistance of the aluminum oxide coating.
? Emuge Corp.
508-595-3600 /
emuge.com Hypertherm
800-643-0030 /
hypertherm.com Iscar Metals Inc.
817-258-3200 /
iscarmetals.com Kennametal Inc.
724-539-5000 /
kennametal.com
Sandvik Coromant 201-794-5000 /
sandvik.coromant.com/us Seco Tools LLC
248-528-5200 /
secotools.com/us
Walter USA LLC 800-945-5554 /
walter-tools.com/us
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