AERO-DIANAMICS™: SHAPING PRODUCTIVITY IN AEROSPACE
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SHAPING PRODUCTIVIT Y IN AEROSPACE ——— Advanced PCD round tool blanks make possible new geometries which break through the barriers in aerospace tool desi

THE CFRP RE VOLU TION —— Revolutionary new CFRP composites and stacks drive airframe weight reduction For example, Boeing’s 787 Dreamliner uses 50% by weight Carbon Fibre Reinforced Polymer (CFRP) composites for fuselage, wings, fin, stabiliser, control surfaces and nacelles. Overall, the use of CFRP in aerospace is forecast to grow by 14% p.a. to 23,000 tonnes by 2020*. Machining these new strong, durable, lightweight and fibrous materials requires new technology. That technology is the new Aero-Dianamics range of Polycrystalline Diamond (PCD) round tools blanks. Aero-Dianamics allows the...

TOOL DESIGN SE T FREE —— Revolutionary new PCD tool blanks break through barriers in aerospace tool design WING SKIN WING STRINGER WING RIB WING SPAR VERTICAL TAIL SPOILER OUTER FLAP HORIZONTAL STABILISER KEEL BEAM PASSENGER DOOR OPENING CARGO DOORS AND OPENING FAN BLADE CENTRAL WING BOX FUSELAGE COCKPIT WINDOW OPENING PYLON AND FAIRINGS NACELLE COWLINGS PASSENGER WINDOW OPENING LANDING GEAR DOORS AND OPENING Tool designers can now create entirely new PCD tool geometries breaking through the existing barriers in PCD tool design with: Element Six’s Aero-Dianamics range has two portfolios...

AERO -DIANAMIC S RE VOLU T IONARY DRILLING MAT ERIAL S UN IQUE PL A N A R AD -D 3 B L ANK S FOR COMP LE X D R ILL G EOM E TR I ES –– Almost infinite flexibility in drill point geometry –– Significantly increased wear resistance over traditional coated carbide drills –– Tool life more than 10* times longer than tungsten carbide drills –– Consistent performance over the tool life –– Greater cutting point flexibility –– PCD physically bonded to substrate, not brazed –– Superior work piece surface finish –– Large rake angles possible for lower tool forces –– Multiple re-sharpenings possible ––...

BRE AK ING T HROUGH E X IS TING BARRIERS IN PCD TOOL DESIGN AD-DRILLING HEL I X CU T T ING A NGL E T O C OPE W I T H A L L A PPL IC AT ION DEM A ND S –– Flexibility to optimise design to meet work piece application demands DUA L A NGL E DRIL L P OIN T GEOME T RY –– Provides flexibility in determining drill cutting points –– Included angles up to 90° can be achieved MULT IPL E F L U T E S –– More flutes result in lower forces, better chip evacuation and faster drilling speeds –– Tool designers not constrained by planar PCD shape –– Provides enhanced design flexibility –– Designers have...

NE W T OOL S ENABLING NE W LE V EL S OF PRODUC T I V I T Y —— The five leaps in tool performance that deliver exponential increases in productivity PCD is the hardest man made material in industrial use. Its wear resistance far exceeds that of tungsten carbide. The use of PCD extends tool life by a factor of at least 10* times. Moreover it maintains optimum sharpness throughout the life of the tool. * The University of Birmingham, UK. PCD drills and end mills produce consistent hole and edge quality for significantly longer than coated carbide tools. Tools can run faster with PCD as it has...

DELI V ERING AN AT TR AC TI V E COS T OF OW NERSHIP SOLU TION Aero-Dianamics has been shown to be a proven cost effective solution for machining the latest generation of composite materials. Aero-Dianamics Planar and Chevron tools significantly reduce the total cost required to drill 10,000 holes compared to competitor veined PCD, CVD and tungsten carbide tools. Representative examples are outlined below. Results are taken from current testing, with further tests ongoing. More information available upon request. MILLING Aero-Dianamics Helix tools significantly reduce total time required to...

ELEMENT SIX Element Six, part of the De Beers Group of Companies, designs, develops and produces synthetic diamond and other supermaterials, and operates worldwide with primary manufacturing facilities in China, Germany, Ireland, South Africa, the UK and US. Element Six supermaterial solutions are used in applications such as cutting, grinding, drilling, shearing and polishing, while the extreme properties of synthetic diamond beyond hardness are opening up new applications in a wide array of industries such as optics, power transmission, water treatment, semiconductors and sensors. If you...