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.
STOBER develops new generation of planetary gear units
The new generation of servo planetary gear units from STÖBER Antriebstechnik offers drives that are the most compact on the market in their power range and with their diversity of combinations and options. What’s more, any motor series can be directly attached in any available size. This variability allows STOBER to create the right drive solution for any application. In contrast to the prior generation, STOBER also equips the new planetary geared motors with an electronic nameplate, which makes commissioning controllers and drive controllers much faster.
STOBER has developed the third generation of servo geared motors, which are the most compact drive solutions on the market with their level of versatility. To achieve this, the lengths of the new gear units were significantly reduced. All STOBER motors, such as the EZ series or sensorless Lean motors, can be directly attached without an adapter, in any desired size.
Thanks to this compactness, the user benefits from a smaller installation space, lower weight, greater torque and a resulting power density that is increased by up to 65%. The mass moment of inertia is lower because the motor adapter is no longer needed, which allows the full dynamics of the drive to be used. This is a real advantage for the customer, particularly noticeable with small and medium sizes in shorter cycle times.
The new generation also features the highest backlash stability and ruggedness. The excellent housing and gearing quality ensure high acceleration torques as well as the highest running accuracy and precision at the same time. Users benefit from acceleration torques increased by 60%, a speed increase of 45% and an increase of the torsional stiffness by up to 50%.
Flexibility from the Motor Attachment to the Bearing System
The most impressive feature of the new generation of planetary gear units is its enormous variability. This means that not only are the gear units able to be combined with different STOBER motors via direct attachment, they can also be attached to all third-party motors in any size using variable adapters. The drive specialist offers a one-of-a-kind interface technology for this purpose. STOBER motor adapters are available with different couplings as well as in the ServoStop variant with an integrated brake. The adapters can also be combined with standard or reduced-play gear units. In particular, the large design of the STOBER adapter with an extra-large motor plate makes it possible to connect the most compact STOBER gear units with motors of very large sizes—a truly unique selling point.
Depending on the application, another advantage compared to the competition is that the right bearing can be selected, whether deep-groove ball, cylindrical roller or angular contact bearing. These low-friction bearings enable generally higher speeds.
Thanks to this enormous variety, engineers have all the options in the design phase to put together exactly the right drive solution for any application. A smaller motor to optimize efficiency? A smaller drive controller might go well with that—which also lowers costs.
Easier Commissioning Thanks to Added Electronic Nameplate
Another special feature of the new generation is the electronic nameplate. In combination with the STOBER electronics, every geared motor automatically sends its electronic, mechanically relevant data by plug and play to the corresponding drive controller upon commissioning. As a result, the geared motors are uniquely identified. This eliminates high-effort, error-prone parameterization, which shortens the total system configuration significantly.
STOBER will present the new generation of servo planetary gear units for the first time at the SPS IPC Drives in Nuremberg, hall 3A booth 451 at the end of November. Sizes 2, 3 and 4 will be available from 1st October 2019, sizes 5 and 7 from 1st March 2020 and sizes 8 and 9 from 1st May 2020.
Low voltage Dc Servo Motors that redefine performance expectations
Precision motor specialists INMOCO is launching the first of a series of low voltage DC servo motors to meet the need of new and emerging applications in robotics, automated guided vehicles (AGV), medical equipment and other fields.
Made in the US as an extension to Kollmorgen’s AKM2G portfolio of servo motors the new low voltage range includes 24Vdc, 48Vdc, 72Vdc and 96Vdc units as standard, with options to go up to 105Vdc.
The first motor available form INMOCO is the AKM2G Size 3, Connector version, which includes M23 SpeedTec (dual) and htec (hybrid) connectors as standard options. There is a choice of feedback options, including absolute encoder, commcoder or resolver.
Expected during fourth quarter of 2019, further options will be available, including Size 3 flying lead versions and Size 2, Size 4 with both flying leads and connectors.
With windings specially designed for low voltage applications, the new AKM2G motors have been designed for high power and torque density, thus offering more optimised motion performance.
The AKM2G series represents the latest generation of synchronous servo motors and are available in powers from 0.3kW to10 kW. They are designed to provide continuous torque up to 30% greater than earlier servos and support a wide range of feedback, brake, thermal sensor and seal options.
The greater power output offered by the AKM2G motor means OEMs can design compact high performance machines, while end-users can upgrade existing machinery to increase speed and/or throughput.
Established in 1987, INMOCO now offers an extensive range of motion control equipment including: compact servo amplifiers, position controllers, stepper motors, PLC controllers, linear motors, sensors, electric actuators and gearheads. INMOCO’s product portfolio is supported by extensive applications and technical expertise, in addition to customer-specified electro-mechanical development and sub-assembly services; including calibrating and testing in a class 10,000 clean room facility.
Bonfiglioli develops sustainable digital solutions to continuously optimize the plant life cycle
Benefits of the integration of synchronous reluctance motors and dedicated frequency inverters.
Bonfiglioli is constantly looking for optimizations to offer innovative solutions for industrial motion control to increase the machine performance and its competitiveness, high control performance and high energy efficiency. Nowadays, this last aspect becomes increasingly relevant, both because of environmental considerations and for cost savings related to the plant life cycle.
To address these requirements, Bonfiglioli has developed a Power Drive System in its research centers; this system combines BSR series reluctance synchronous motors with Active Cube frequency inverters with dedicated sensorless vector control. The motor is compatible with the wide range of Bonfiglioli industrial geared units.
This solution is available in two packages, with optimized compactness for small spaces or operation costs reduction respectively, both with excellent efficiency levels (Class IE4 for the motor, and class IES2 for the Power Drive System, according to the actual Ecodesign Standard EN 61800-9-2).
In comparison to conventional motor-frequency inverter solutions, the Bonfiglioli Power Drive System allows minimizing the overall energy consumption in the different operation points. The motor control is realized with a complete mathematical characterization of the motor, which also ensures a simple and reliable system configuration.
The full package integration and the wide range of available software control strategies bring additional performance benefits: accurate sensorless speed control, stable torque control, high torque even at low or zero speed and excellent overloading characteristics.
Overall, this solution is ideal for a wide range of industrial applications; it can be fully integrated in Industry 4.0 plants, thanks to the advanced drive digital connectivity and Bonfiglioli IOT platforms, presented during the 2019 SPS Italia (District 4.0) in combination with this Power Drive System.
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