of tooling, then here are the speeds, feeds, and fl ows you should be running with cryo. And we’re continuously adding to that library.”
The List of Cutting Tool Partners Should Grow 5ME has partnered with Star Cutter and others to produce carbide blanks and a dozen small-to-medium cutting tool manufacturers to produce a line of cryo-enabled carbide cutting tools, to include indexable milling, drilling, turning, and boring tools, as well as solid carbide milling, drilling, thread milling and reaming tools. These tools have all been developed and tested for optimal cutting performance when machining with cryogenics. At this point, all the tools are branded 5ME. But Tecos
said his fi rm is working with Sandvik, Kennametal and Inger- soll to also provide the tools, because “as we’re selling this technology into companies like Lockheed Martin, they’re go- ing to want the option of purchasing their tools from the big names that they’re used to purchasing from.” 5ME has proven-out turnkey tooling solutions for
aerospace structures (both thin wall and pocketing tasks), aeronautical engines (blisks and impellers), fluid cylin- ders (fracturing pumps), and engine blocks (facing and cylinder boring).
Here cryogenic drilling has reduced the white layer in RC 40 4340 steel by 50% compared with traditional wet drilling.
But 5ME doesn’t leave you to fi gure this out yourself.
Tecos said the fi rm works very closely with the end-user and the operators to make sure they understand the pro- cess. “In a typical project, we look at the current machining process, speeds and feeds and so forth, and translate that to a cryo process. If we see an advantage in speed or other manufacturing factors, we would develop the parameters for cryo processing. We usually do that in our tech center in Michigan, where we have four cryogenically enabled machines, an engineering staff, and equipment to inspect the tooling microscopically. It’s a balancing act. You want to fl ow just enough liquid nitrogen to counteract the heat that’s being generated.
“Utilizing our Cryo Flow Calculator, we have developed a
pretty good database of the temperatures involved at various speeds and feeds for a variety of tools and materials. So you could say we’re rewriting the machinist handbook from a cryo perspective: If you’re cutting in this material with this type
The ‘Side Benefi ts’ are so Good They May be Enough by Themselves in Some Cases Not only does an internally cryogenically cooled tool cut much faster, you’ve eliminated the need for coolant and the associated tanks, pumps, fi lters, and mist extractors, saving fl oor space and electricity. It also makes for cleaner air, safer fl oors, and fewer dermatitis problems in your shop. And be- cause the remaining chips are dry and clean, you don’t have to wash them before recycling the material. These are ancillary benefi ts, but in some cases they alone may justify the technology. Tecos said “we’ve had some very interesting conversations recently on both the East and West Coasts with regard to reducing water consumption in manufacturing. The amount of water used with coolant is sig- nifi cant, and if you consider drought conditions in California, for example, this technology could have a dramatic impact, literally savings millions of gallons.” Another factor to consider: 5ME is a US fi rm focused (for the moment) on the North American market. Maybe this is an opportunity to grab a lead on the rest of the world.
71 — Aerospace & Defense Manufacturing 2016
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