Aerospace Frame
24Pages

Total component solutions Aerospace Frame

2 Sandvik Coromant in Aerospace Expertise for challenging production Your demands set our standards Aerospace is one of the most technically demanding industries in the world. With increasingly diffi cult to machine materials , exacting specifi cations and constant time restraints , the manufacture of aerospace parts has many limitations - but at the same time, production rates are set to increase. Components and their features Our goal is to offer complete solutions to typical components, this is both the physical tool but also the processing knowledge. In reality, a solution encompassing:...

3 One system! One solution! For your entire workshop Coromant Capto®, the smart choice for aerospace component manufacturing. Coromant Capto is a unique coupling just as suitable for turning centre turrets as for machining centre spindles – the interface with no limitations. This system provides the fl exibilty to optimize the length required to keep maximum stability and radial run out allowing high metal removal. With over 5000 standard products any tooling assembly can be built. Aerospace frame Aerospace frame is a broad defi nition referring to any parts of the aerospace structure...

4 High pressure coolant The recommendation here is simple, always apply coolant when cutting titanium in large amounts and if possible at high pressure. Using high pressure coolant for milling in titanium will double the tool life compared to normal coolant pressure. The critical re-cutting of chips that damages the tool is prevented as welded chips are blown off. Recommendations: ÿ Apply coolant through spindle and tool ÿ Volume and pressure should be carefully planned in relation to the number and diameter of coolant holes and your operation ÿ Nozzle sizes should be kept small to maximize...

5 2D profi le milling For this operation we can provide a total solution from roughing through to fi nishing. The best choice for roughing is CoroMill 690 with specialized titanium grades S30T and S40T. The axial location of the inserts is built into the bottom of the insert to prevent movement and enable high metal removal rates with security. Its design makes it cut light and use minimum power. Each coolant hole is threaded to allow smaller diameter nozzles for high pressure coolant applications. For fi nishing we recommend the Sandvik Coromant long-edge fi nishing cutter, also known as...

6 The central wing box, made out of several types of composite material, commonly stacked with aluminium and titanium challenges the manufacturing process, tool security and surface quality. Issues such as chip evacuation, effective production and hole quailty, are made more diffi cult due to the drastic difference in material properties. Fuselage - central wing box Demanding application in stacked materials Material: Aluminium, carbon fi bre, aluminium stack Application: – Hole making Hole diameter: – 9.525 mm (3/8”) Drill type: – CoroDrill® 854 composite drill with diamond coating Machine...

7 Edging and surface machining For edging of larger components, CoroMill® 390 with PCD inserts or diamond coated carbide inserts will increase removal rates. Using Coromant Capto® clamping units for long overhangs will increase the stability of your operation. Hole making in carbon fi bre and metallic materials With a focus on reduced downtime, improved hole quality and tolerance in carbon fi bre, optimized drill geometries with PCD vein technology and an optimized application process are essential. Whilst one-hit tools reducing production time is always the goal, the fi nishing of a hole...

8 The main challenges for machining these types of structural components are the hole making, edging and surface machining. Wing - wing box CoroDrill® geometry range The new CoroDrill 854 for fi bre rich materials, the new 855 for broad range or the new 856 geometry for resin rich materials are all designed with hole quality in mind. Optimizing the production process is simplifi ed with a choice of geometries with optimized rake and point angles dedicated for specifi c materials, where demands on hole tolerance, reduced delamination and improved hole tolerance is in focus. CoroDrill 854...

9 Edging of composites The fi nish achieved in one operation can reduce or eliminate secondary operations, which together with tool life improvements, contributes to reduced machine downtime. Rough machining or fi nishing of composite materials can be improved with CoroMill®cutters. PCD end mills and diamond-coated carbide cutters can be engineered to suit most applications, reducing splintering of fi bres and increasing metal removal rates. CoroMill®Century, a high precision solution for surface machining with demands on dimensions and surface fi nish. Serrated seat indexable inserts make...

10 Wing - pylon bracket The pylon brackets found on the wing of the aircraft can be of open and closed design. The main challenge for the closed components is the closed angle and the deep slots. Slotting When the slot is deep and narrow, side and face cutters provide the best stability and productivity. The cutters can be built into a gang to machine more than one surface in the same plane at the same time. CoroMill 331 now available with S30T and S40T is an optimized solution with adjustable cartridges. Exchangeable-head milling system The CoroMill® 316 end mill is the fi rst product in...

11 Roughing 3D pockets with closed angles Closed angles; less than 90 degrees, are a common component feature in pockets and cavities. Depending on the stability of machine set-up, the slicing method using CoroMill® Plura bull nose end mill or the plunging method using CoroMill 390 engineered solution is the best choice. Finishing 3D pocket with closed angles A machine with 4 or 5 axes is needed to machine a closed angle. 4 axes: If only one side of the pockets has a closed angle and the bottom shape is fl at. 5 axes: if there is a corner with closed angles on both sides and a radius at the...