2009 03 06 E Machining Modern Materials

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P.O. Box 1520

D-73405 Aalen

Contact Hermann Steidle

Telephone +49 / 73 61 / 5 85 1 24

Fax +49 / 73 61 / 5 85 1 10

e-mail [email protected]

Date 28.04.2009

Press release no. 09-03-06-E

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information

Pressrelease

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MAPAL

Przisionswerkzeuge

Dr. Kress KG

MAPAL tool technology for machining modern

materials such as CFRP and titanium

The subject of energy efficiency plays a crucial role in

the development activities of the automotive and

aerospace industries and in the energy sector. This fact

has been eclipsed somewhat by the currently uncertain

economic situation. But it will come to the fore again.

Energy needs are increasing. Important factors in this

respect are population growth, the increasing quality of

life of the world's population and long-term economic

growth. At the same time, there are limits on the

increase in the consumption of energy, whether due to

global warming, atmospheric and environmental

pollution or limited resources such as oil and bio-fuel,and the resulting increasing prices for energy. The

consequence is that the increasing energy demand must

be covered by improved energy efficiency. The energy

efficiency necessary is acting as a technology driver in

many sectors. This statement also applies to stationary

consumers of energy. Energy saving regulations for the

insulation of buildings or energy figures on household

appliances have long been part of our everyday lives.

Mobile consumers of energy must also become more

efficient in the future to achieve improved effectiveness

of energy. Here motor vehicles and aircraft are of course

key candidates. In actual fact, it is aerospace, the

automotive industry and the energy sector that are the

primary driving sectors for the development of new

materials for reduced component weight. To achieve

lower weights, a lower power requirement and a higher

load capacity, materials are required with a favourable


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P.O. Box 1520

D-73405 Aalen


Telephone +49 / 73 61 / 5 85 1 24

Fax +49 / 73 61 / 5 85 1 10


Date 28.04.2009


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ratio between density and mechanical properties, in

short a low specific density. The most important

examples of these so-called lightweight materials are on

everyone's lips these days: CFRP and titanium, as well as

composites of the two. However, cast materials such as

vermicular graphite cast iron, SiboDur or ADI can be

allocated to this group of lightweight materials, if their

ratio of density to mechanical properties is considered.

The above mentioned lightweight materials have a

further feature in common: they are generally difficult to

machine. In the metal machining industry there is little

experience in these new areas, wider adoption is

progressing only slowly.

MAPAL has been very heavily involved in the machining

of lightweight materials for some years. For this reason

appropriate tool solutions for all applications are

available for machining vermicular graphite cast iron

and SiboDur. Last year very specific tool solutions were

tested and introduced for machining the materials CFRP

and titanium; these solutions make it possible to

machine reliably and cost-effectively.

Cost-effective drilling and trimming of CFRP

Carbon-fibre reinforced plastics, CFRP for short, with

high strength and stiffness along with low specific

weight, are lightweight materials par excellence. Initially

used for Formula 1 car chassis, the applications in

aerospace and in automotive manufacture are

continuously increasing. After initial working to close to

the final contour, the extremely abrasive materials are

further machined to produce finished components. To

prevent damage to the part (e.g. delamination,


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P.O. Box 1520

D-73405 Aalen


Telephone +49 / 73 61 / 5 85 1 24

Fax +49 / 73 61 / 5 85 1 10


Date 28.04.2009


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Dr. Kress KG

protruding fibres at the edge of the workpiece), special

requirements are placed on the tools.

Currently drilling rivet holes is the primary application in

CFRP and places high requirements on quality and tool

life. MAPAL uses solid carbide drilling and counterboring

tools with a diamond coating for this machining. Using

this tool, chatter marks on the countersink and

delamination at the exit are prevented. Very high

accuracies are achieved.

Application data for the diameter range

4,1 5,47 mm:

Bore tolerance: 8 m

vc = 85 m/min

f = 0.08 mm

vf = 440 mm/min

As an alternative solid carbide drills with a special

geometry are used.

For trimming CFRP various solid carbide milling tools

have been introduced in practice that are used with

parallel feed. To reliably achieve the required surfacefinishes during trimming, MAPAL uses PCD-tipped end

milling cutters from the HP-EndMill range as an

alternative to these so-called routers. These powerful

tools have three or four blades and impress with low

wear. They are used with counter feed.

Cost-effective titanium machining with optimised tool

solutions

Primary application areas for titanium are in the

aerospace industry for components in engines, the

undercarriage and fuselage, in automotive manufacture,


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P.O. Box 1520

D-73405 Aalen


Telephone +49 / 73 61 / 5 85 1 24

Fax +49 / 73 61 / 5 85 1 10


Date 28.04.2009


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and also in the medical sector (implants). Titanium is a

long-chipping material. Due to the high temperatures

reached at the cutting edge, low cutting speeds are

necessary. In addition, clamping system and machining

must be absolutely stable, as otherwise minor vibrations

may occur.

Two tool solutions are in use for milling titanium. For

finishing a replaceable milling cutter with torque

transfer connection is used, which provides optimal

torque transfer and high reliability due to low radial run-

out error. The replaceable milling heads are easy to fit, a

MAPAL Module connection is fitted to the tool holder

that can be used to compensate for the radial run-out

error.

For roughing an ISO tangential milling cutter is used that

achieves enormous material removal rates.

Example application on a structural part (fuselage/wing

joint) in titanium Ti6Al4V with a cutting depth apof 75

mm and a cutting width ae of 25 mm:

vc = 70 m/min

n = 350 min-1

fz = 0.12 mmvf = 168 mm/min

Material removal rate: 315 cm/min

The MAPAL high performance reamers from the HPR

range are particularly suitable for reaming in titanium as

they permit high cutting speeds and feeds. For example,

joint parts for the wing made of titanium Ti6Al4V are

reamed using a six-bladed HPR reamer 30.176 mm. To

achieve the required accuracies, additional guide pads

are fitted to the tool holder.


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P.O. Box 1520

D-73405 Aalen


Telephone +49 / 73 61 / 5 85 1 24

Fax +49 / 73 61 / 5 85 1 10


Date 28.04.2009


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Machining composite materials

Titanium is also becoming increasingly important as a

sandwich material in combination with CFRP or

aluminium, to significantly strengthen components with

heavy loads in structural parts, for example the

fastenings for wing flaps.

CFRP materials are often used in combination with

titanium, with aluminium or with aluminium and

titanium. For machining the tools must be optimally

designed for both or all three materials.

For drilling from the solid in these composite materials,

MAPAL uses PCD drills. The tool must achieve a high

constant diameter tolerance. At the same time the

formation of burrs on the titanium and aluminium as

well as protruding fibres and delamination of the CFRP

must be prevented. Low costs per bore and long tool life

complete the advantages of the PCD sandwich drill.

Example application 9.3 mm in CFRP-Ti multilayer:

vc = 27 m/min

n = 900 min-1

f = 0.02 mmvf = 18 mm/min

Summary

The increasing importance of energy efficiency is

undisputed. For this reason lightweight materials will be

used increasingly in the future. Despite the difficulties

that may arise during machining, the costs per part must

not increase.

For this reason new tool solutions are required that

permit a complete understanding of the process. At the


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P.O. Box 1520

D-73405 Aalen


Telephone +49 / 73 61 / 5 85 1 24

Fax +49 / 73 61 / 5 85 1 10


Date 28.04.2009


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MAPAL

Przisionswerkzeuge

Dr. Kress KG

same time, tools are required to have high productivity

and the machining must be of high quality to keep the

costs per part low or to reduce the costs. MAPAL has

tackled this issue and developed tailored tool solutions

for these requirements. The result is reliable, high

performance tools for all machining tasks and all

materials in the lightweight materials sector. MAPAL has

prepared itself for the future, in this sector as well.

Aalen, April 2009

Captions:

Pic 1: Rivet holes in CFRP are precisely machined with a

diamond coated drilling and countersinking tool.

Pic 2: A replaceable head milling cutter with TTS connection

is used for finish milling of titanium.

Pic. 3: The ISO tangential milling cutter for roughing

titanium achieves enormous material removal rates.

Pic. 4: A PCD-tipped drill is used for machining stacks of

CFRP/titanium or CFRP/aluminium.


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Pictures

2009-03-06, pic 1

2009-03-06, pic 2

2009-03-06, pic 3


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2009-03-06, pic 4

2009 03 06 E Machining Modern Materials

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