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High-feed side milling cutters boost ISO S material machining ideal for aerospace industry.

To enhance milling performance on ISO S materials, cutting tool and tooling system specialist Sandvik Coromant is introducing a series of end mills featuring unique geometries and grades. The CoroMill® Plura HFS (High-Feed Side milling) ISO S cutters deliver reliable and productive results on workpieces made from titanium and nickel-based alloys, bringing benefits to both aerospace engine and frame applications.

To help address the predicted growth in aerospace business in the coming years, the CoroMill Plura HFS range comprises two end-mill families optimised for titanium alloys, and one for nickel alloys. As chip evacuation and heat are specific challenges when machining titanium, Sandvik Coromant has developed a solid version for normal chip evacuation conditions, and another featuring internal coolant and a new cooling booster (patent pending) for optimum swarf and temperature control.

The end mills for titanium are available in GC1745 grade, which is based on a tough, fine-grained (sub-micron), cemented-carbide substrate with sharp, controlled edges for very tough milling operations. Furthermore, a new multi-layer coating that contains silicon provides excellent wear resistance and low thermal conductivity. The geometry of the cutters is based on a six-flute concept with no centre cut and uneven tooth pitch. Additionally, the core dimension has been optimised for higher stiffness in titanium alloys, while the corner radius, rake angle and relief are all designed specifically for machining these challenging materials.

For nickel alloys, grade GC1710 is deployed, which also features sharp, controlled cutting edges. A hard, wear-resistant, fine-grained substrate is optimised to resist high working loads when machining hard, highly adhesive, work-hardened materials such as aged Inconel 718. Here, a new coating produced with innovative HIPIMS (high power impulse magnetron sputtering) technology also offers adhesion reducing properties to avoid the formation of BUE (built up edge) and increase tool life.

“The new cutters are designed to offer high-feed side milling with large axial depths of cut (ap) and low radial depths of cut (ae), along with a controlled maximum chip thickness, so that the cutting forces are managed and provide a smooth cutting action” explains Tiziana Pro, Global Product Manager Solid End Mills at Sandvik Coromant. “The result is two-fold: increased productivity provides higher output, while greater tool life and reliability reduces scrap rates in what are typically high-value components. Further customer benefits include reduced tool cost per component and greater safety levels.”

Target aerospace components include titanium wings and pylon parts, as well as engine cases made from Inconel 718. Applications in sectors such as oil and gas, medical and motorsport, where titanium and nickel alloys are becoming increasingly prevalent, will also benefit.

To highlight the potential gains on offer, a customer trial was performed involving an LPT (low-pressure turbine) case made from aged Waspaloy 420 nickel-based alloy. Using a horizontal machining centre, axial depth of cut was increased and radial depth of cut reduced (high radial forces are known to create deflection issues). Comparing a 12mm diameter CoroMill® Plura HFS end mill against a competitor cutter of the same size, metal removal rate increased substantially, leading to an impressive 198% increase in productivity. As a result of this success, the customer has committed to ordering the new cutters from 1 October 2017.

Türkiye endüstrisine, alana özel, spesifik yayınlar üreten MONETA Tanıtım’ın sektörel dergilerinin editörlüğünü yapmaktayım. Yeni nesil, dinamik yayıncılık anlayışıyla, dijital ve basılı mecralarda içerik geliştirmek için çalışmaktayız.

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Motors

NORD smooth motors ideal for the food and beverage industry

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From its own production, NORD DRIVESYSTEMS offers ventilated and unventilated motors with smooth surfaces for areas with high hygiene standards. Their washdown-optimised cast aluminium housings make them easy to clean.

The smooth surface motors from NORD are available in sizes BG 80, 90 and 100. They are based on the NORD modular construction system and therefore offer maximum flexibility for versatile application areas. The motors are provided with protection class IP66 and they are compatible with every gear unit type. In addition, the use of energy-saving three-phase motors ensures high efficiency with low operating costs.

Optionally, the smooth surface motors are available with the nsd tupH surface treatment, which is a special process making the aluminium surface corrosion-resistant and particularly hard, similar to the qualities of stainless steel. In contrast to protective painting or coating, nothing can detach or flake off.

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Motors

Shaft height record for high-torque motors

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Baumüller is expanding its portfolio of high-torque motors with a shaft height of 560 mm.

Baumüller is breaking its own shaft height record with the current expansion of its motor portfolio. With a shaft height of 560 mm, the new DST2-560 high-torque motors are now the largest motors that the manufacturer and pioneer of direct drive technology offers in series production.

High torque for industrial use

With a maximum torque of up to 80,000 Nm, the motors are suitable for use in various industries and systems, such as servo presses, extruders and shredders. The water-cooled high-torque motors offer very high torques even at low speeds and also impress with outstanding true running characteristics, a robust design and a smooth housing surface that is not prone to accumulating dirt.

Powerful and clean alternative for ships

Specifically designed for use in ships, the DST2-560 is optionally also available with so-called wing mounts. These feet diametrically arranged on the outer diameter of the motor make it easier to integrate it into the ship design. In addition, the high-torque motors have already been prepared for approval according to Lloyd’s Register and the DNV GL. With degrees of efficiency of 96% over a broad speed range, the DST2-560 motors are very energy-efficient.

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Motors

Module systems with higher performance

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The drive and automation specialist Baumüller is introducing new axis units for its module system b maXX 5000. The new units are suitable for a performance range with a peak performance of up to 240 kW. The entire range of b maXX 5000 devices covers a nominal power range of 1 to 100 kW and thus displays a suitable solution for various applications in machine and plant construction

Safe stackable servo controller

The converter series b maXX 5000 includes feed-in and regenerative units as well as drive units, which can be quickly and easily combined by an integrated drive connect system. For the machine builder and operator this means less installation effort and short start-up and service times. The controllers are available in the air, water and cold plate cooling types and score with minimal assembly space thanks to high performance density. With plug-in modules the devices can be equipped with safety functions according to IEC 61800-5-2. The machine builder can choose from four different modules to adapt the safety functions to his specific application. The plug-in modules enable a fast and flexible reaction to new requirements.

 

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