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.
Shaft height record for high-torque motors
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.
Module systems with higher performance
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.
The all-around solution in metal machining
Everything is turning: AKM servomotors from KOLLMORGEN in CNC multi-spindle machines from INDEX. The MS40C-8 from Index is designed as a CNC multi-spindle machine for large and small production batches.
MS40C-8 is the name given to an eight-spindle metal processing machine from INDEX for fully-automated production of complex components. Yet with double 4-spindle machining, the same machine is also available for cost-effective production of simple parts with double the output quantity. There are a number of good reasons why the CNC multi-spindle machine, made in Deizisau near Esslingen, southern Germany and driven by KOLLMORGEN servo technology, is seen as a true all-around solution in machining technology.
The solution from INDEX is used both in the production of high quantities of precision parts and – due to their shorter set-up times – for smaller batches. “We are pioneers in CNC multi-spindle machines,” says Karl-Heinz Schumacher, head of development and design of multi-spindle machines at INDEX. There are currently several thousand of these machines in use around the world.
Demand for dimensional accuracy
INDEX specializes in both selling standard machines and also supplying fully equipped machinery with all tools assembled. Multi-spindle machines are mostly used for parts that will be on the road at some point in the future. These include injection pump components, valve needles, small gears or injector nozzles – all featuring accuracy levels within tolerance grade IT5.
The centerpiece of the INDEX MS40C-8 multi-spindle automatic lathe is the compact spindle drum with eight fluid-cooled motor spindles using synchronized technology. These can reach speeds of up to 7,000 rpm with 24 kW of power and torques of up to 57 Nm. They feature infinitely variable speed control, high torques, and a compact design; and they require no maintenance. As a result of the increased number of main spindles and tool carriers, the
MS40C-8 is also completely capable of machining highly complex components in a single operation. There are also two pivoting synchronous spindles available, each able to work on up to seven rear-end machining tools, with four of these capable of being powered. The capacity for two rear-end machining tools to work on the workpiece at the same time is a new feature.
Perfect workflows for perfect parts
In all cases, the optimum speed and feed rate can be programmed for each spindle location and each cutting edge, and these can even be modified during the cutting process. The eight fluid-cooled motor spindles integrated in the spindle drum are infinitely variable, require no maintenance, and are driven with synchronous motors. The KOLLMORGEN AKM permanent magnet servomotors are installed in the cross slides. The synchronous machines in the INDEX systems also include the added benefit of high-quality control mechanisms and high torque density. The optimum power-to-volume ratio allows INDEX to work with smaller drives during the design process. Careful use of space is a particular benefit in confined work areas.
High torque density
Plenty of power with minimum space: INDEX uses the KOLLMORGEN motors in part as positioning axes for the tools. The high-power density enables compact designs that take up less space when installed in the work area. The very good torque density of the AKM synchronous servomotors allows INDEX to convert the rotation movement of the motors into a linear motion without gears. The ball bearing spindles are connected directly to the motor shaft for this. “The lack of gears means there are fewer moving parts, and improves the zero backlash and the overall stiffness of the drive,” says Metin Han from KOLLMORGEN. As Key Account Manager he took INDEX´s requirements on board and translated these into a suitable design solution. “We need zero backlash and stiffness, especially with multi-stage thread cutting, so that the tool always completes the next machining step precisely on the threaded attachment,” explains Karl-Heinz Schumacher.
Drives directly in the work area
INDEX uses these features without having to clad the AKM synchronous servomotors in the work area beforehand–a time-consuming process. The AKM servomotors are specially designed to meet the requirements provided by INDEX and undergo extensive IP67 testing in the aim of keeping the work area as orderly as possible. The motors can be installed directly with the cross slides thanks to their special washdown exterior paint. This allows the units to be introduced directly into the machining process without impairing their service life. “That´s a good argument for the AKM servomotors from KOLLMORGEN”, says Karl-Heinz Schumacher. This just leaves the connecting cables. These are also exposed to constant bombardment from metal chips. As a result KOLLMORGEN placed these in a metal cable duct specifically designed to meet INDEX´s needs. Today, this co-engineering initiative securely protects the servo drive, together with its wiring, from the metal chips that fly around and from the cutting oil that gets into the work area at pressures up to 80 bar. Integration standards are maintained even though the AKM synchronous servo motors from KOLLMOREN are perfectly aligned towards the usage conditions in the INDEX CNC multi-spindle machines as a result of the co-engineering project. Background: the motors need to fit seamlessly into the machine´s overall automation mechanism without time-consuming adjustments. The connection via DRIVE-CLiQ is an example of this. This allows the performance benefits of the AKM synchronous servo motors to be used for CNC applications
directly with Sinumerik control units in metal machining, without needing to compromise on the connection technology. Until now, anyone who wanted to use motors from other manufacturers outside these Siemens world proprietary motors had to rely on special and costly DRIVE-CLiQ sensor modules. “DRIVE-CLiQ is available for the AKM motors, allowing us to continue processing the position signals 1:1 without requiring any SMC modules. They cost space and money,” notes Metin Han. “This leaves us free to exploit the performance benefits of the AKM motors in full in this application.”
The Bottom Line
Fitting with DRIVE-CLiQ is an example of how the synchronous servo motors from KOLLMORGEN can adapt to the diversity of CNC and automation technology – particularly for metal machining. This lets machine constructors use drives outside of closed systems, without losing any of the convenience or performance benefits. Very simple adjustments can also be carried out outside of mass production, opening up whole new avenues for INDEX – from gearless use of the AKM servo motors to protection for the connecting cable using a specially developed cable duct.
2. The AKM servo motors have been co-engineered for use at INDEX with a lasered nameplate and special cable duct.
3. “The AKM servo motors are simply compact”: Karl-Heinz Schumacher, head of development and design of these machines at INDEX.
4. The machining centers are very easy to use–a prerequisite for high levels of
5. The steel rods are machined in eight different work steps.
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