CUTTING TOOLS
difference if you don’t apply them when machining aluminum. Failure to apply these principles while machining alloy steel may negatively affect tool life as well as surface fi nish and dimensional control. Failure to apply these principles while machining titanium or a high-temperature ally could result in catastrophic failure, dramatically increasing production costs,” said Carrington.
chinability, if the 6 Al-4V is factor of 100, Triple 5-3 is around 55-60, 10-2-3 is around 60-65, and Beta 21s is 50-55.” Walter has been engaged in an ongoing program to de- velop new technologies in carbide insert cutting geometries and coatings as well as a new confi guration of tool bodies. Targets for these inserts and tools are structural machin- ing applications like spars, pylons, landing gear, fl at tracks, and other internal structure parts, principally in titanium. “In testing, we have achieved more than an hour and a half of intensive cutting in titanium with remarkably low insert cutting edge wear. The industry prefers less than 0.015" [0.38-mm] wear. In our test environment we were down between 0.004 and 0.006" [0.102, 0.152 mm],” said Maples. “Walter’s goal was to achieve 20 in.3 cm3
] or more material removed per minute for a minimum of 60 minutes. They have been able to achieve over 24 in.3
[393 cm3 ] of metal removal
per minute up to 90 minutes. Higher material removal rates were achieved, but the insert edge life drops off.”
Emuge supplies TiNox-Cut high-performance roughing end mills for aerospace machining and other demanding applications.
Iscar’s FTP high-feed milling cutter with a 12.5° approach angle continues the trend toward improving metal removal rates by transferring more of the machining forces axially as opposed to radially. This allows for higher metal removal rates on lighter duty machines as well as long overhangs. “Axial chip thinning allows us to increase programmed chip loads from a more conventional .005-.008 inch per tooth to rates as high as 0.040–0.060 inch per tooth. Due to the 12.5° approach angle, the actual chip thickness is ap- proximately 20% of the programmed load. It is important to create enough thickness in the chip to carry heat away from the cutting zone, providing better metal removal rates and extending tool life.”
New Family of Titanium Cutters Set to Debut “Titanium machining is one of our main focuses right
now,” said Kevin Maples, aerospace solution engineer, Walter USA LLC (Waukesha, WI). “The titanium we are generally working with are 555-3, 10-2-3, 6 Al-4V, and Beta 21s, the latter of which is a fairly recent material development. Each has their own characteristics with 6 Al-4V accounting for about 70% of the aerospace market. To give a basis of ma-
54
AdvancedManufacturing.org | January 2016 The new family of standard products will
feature tangentially mounted inserts, with four cutting edges on the periphery, two specifi ed radii
on the front stations. The periphery inserts are designed to be interlocked, providing a more rigid tool and permitting ad- ditional tool body cutting rows. Anticipated product offering will range from 1.75" (44.4 mm) to 3–4" (76.2–101.6 mm) . The new product grouping which is already in testing with customers around the world will be introduced around the end of the fi rst quarter. Walter has developed a new process for its coatings
aimed at removing stress factors out of the coating to elimi- nate chipping or fl aking. To remove heat from the insert and part more effectively, Walter’s process blasts the top surface of the insert to remove high spots so that the transition from the edge to the chip enables heat to go into the chip so that thermal cracking, notching, and chipping are eliminated.
Tapping, Threading Products for Titanium According to Marlon Blandon, thread mills product
manager, Emuge Corp. (West Boylston, MA) offers a complete solution for today’s titanium challenges in the aerospace industry, ranging from drills, taps, and thread mills to end mills such as TiNox-Cut, designed specifi cally for machining titanium.
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