Aerospace Engine Total component solutions
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: spindle interface tool holder suited to access the component shape programming methods insert grade and geometry surface integrity - correct parameters to leave the component in the best condition The focus: 1) Reducing your non-cutting time - the only time the machine is making any money is when the green light is on. This is where the adoption of machines that are more fl exible, modular tooling systems and high pressure coolant will make a big impact. 2) Optimising the cutting process - when programming for the fi rst time - even if this is a prototype - this is the time to implement best practice for each component feature. Our specialized Application Centers invest in the future of solutions and in the understanding of an industry that goes way beyond tools. Sandvik Coromant in aerospace holds the expertise you need for challenging production, an expertise that puts your success in focus. 2
Coromant Capto and high pressure coolant for green-light production Investing in the future When the component costs tens of thousands, the programming time can be weeks, the manufacturing time is tens of hours and you will be making this part for years; you need to get it right from the start. The Coromant Capto system provides the ultimate rigidity and fl exibility required for machining high temperature and titanium alloys it is the coupling to secure solutions. Balanced and concentric High torque transmission Delivery of coolant to the cutting edge Stable with long tools Withstands high axial forces Quick change Flexible Automatic tool change - No limitations on spindle rotation speed - Without keyways - Through tool delivery - Good bending stiffness - High axial clamping force - ½ turn clamp and release - Modularity to break down and build assemblies - Hydraulic, gripper and magazine storable Our product assortment of over 5000 standard Coromant Capto products support typical aerospace component features in all machines used by the industry. CoroTurn HP - green-light production High pressure coolant is now a standard option on most premium lathes and multi-task machines. Coromant Capto automatically plumbs the coolant to the nozzles. The precision nozzles accurately target the correct point on the insert at a low trajectory creating a hydraulic wedge between the chip and the rake face of the insert. The benefi ts: High-pressure coolant! Chip control Reduced stoppages Fixed precision nozzle More secure process Increase tool life +50% Increase productivity +20% cutting speed The relatively small investment to have the machine optimized for high pressure delivery offers a very fast payback with continual delivery. Investing in Coromant Capto is the gateway to secure and productive aerospace manufacturing - coupling the best interface to secure productive solutions ensures that we are pioneering your future success. 3
Turbine Disc These complex turned parts in hard to machine alloys such as Inconel 718, Waspalloy and Udimet 720 generally feature profi led pockets with various diffi cult clearance requirements. A complete package of standard tools together with uniquely productive solutions is readily available to deliver stable machining to any turbine disc feature. The modular SL70 tooling system Due to tough material, accessibility and productivity, round inserts offer the best method and are used in both roughing and fi nishing. CoroTurn SL70 blades designed to fi t the typical profi ling and pocketing features Oval coupling offers excellent stability and accessibility All radial and axial clearance requirements covered in a compact program Multi-task and vertical turning lathe requirements met with Coromant Capto size C6 Carbide RCMT and CoroCut grades have high pressure coolant as standard Optimized programming and optimised tools give optimized results By choosing trochoidal turning for the roughing operation over the more traditional ramping method, productivity can be doubled with improved security and tool life. Grade CC6060 allows for larger depths of cut to be taken Reduced number of passes required using trochoidal turning Green-light production secured, controlled, predictable wear Pocket dia 500mm - width 60mm - depth 40mm RCGX 120700E 6060 Ramping Trochoidal Cutting speed v c m/min 250 250 Depth of cut a p mm 2 3 feed rate f n mm/rev 0.15 0.2/0.1 Metal removal rate Q cm 3 /min 75 150 Number of passes 40 14 Tool life min 6 4 Number of insert changes 14 7 Time for pocket min 70 29 4
CoroCut angled inserts Perfectly formed for those diffi cult to access grooves, 90 degree angled inserts come in a variety of shapes all as standard. No need for special tools. Blanks even available for dedicated 90, 45 degree and T-profi les. Scallop milling Our exchangeable-head system with CoroMill 316 is the economical tool for scallop milling. With a shorter cutting length than other tools, it provides essential stability, optimized for these small depths of cut with close tolerances. Tool change and tool setting times are drastically reduced compared to traditional end mills and chucks. Chamfering inserts are also available in the same system. Finishing profile with SL70 CoroCut HP S05F For the highest productive fi nishing with excellent surface integrity and dimensional accuracy, the combination of SO5F and CoroCut RO geometry sets the standard for critical part fi nishing. High-pressure coolant! 5
Turbine Casing Typically made from Inconel or Waspalloy, these most challenging of materials pose problems, not so much in the turning operations, but particularly with the amount of milling required in manufacturing this component and the large amounts of material to be removed. Dramatic productivity increase with ceramic turn miling To be successful with this type of application careful process planning is required. Unlike the conventional optimized method with carbide, ceramic face milling runs at a speed of 1000m/min, removing the same amount of metal but 5 times faster. For best results, follow the guidelines of our dedicated HRSA application guide. Ceramic Carbide Application Conventional/up milling Climb milling Coolant Dry Wet Insert RNGN 120700 E 6060 CM300-1204E-MM 2040 Cutting speed v c m/min 1000 30 Diameter D 3 mm 63 63 Spindle speed rpm 5052 152 Feed rate f z mm/tooth 0.1 0.3 Number of teeth Z n 4 6 Depth of cut a p mm 1.5 2 Radial immersion a e mm 35 35 Metal removal rate Q cm 3 /min 106 19 Tool life TL mins 4 25 Total material removed Q t cm 3 424 477 6
Rough milling around a boss For productive secure machining use CoroMill 300 with a roll in programme combined with round inserts to reduce notch wear and allow high feed rates. Helical ramping a hole from solid Helical ramping of larger diameter holes with CoroMill 300 provides the most secure and productive method here. The cutting forces are much lower than drilling, which also struggles with the interrupted exit into the bore. Ramping down to 32mm hole diameter is possible and CoroMill 300 also comes with the advantage of Coromant Capto coupling and through spindle coolant. For best results, we recommend you contact your representative to get this right from the start. Finish profile milling - walls and bores Hole making in aero engine casing For hole making please refer to page 15. Utilise high speed machining techniquesshallow radial cuts and high axial cuts, for productive semi and fi nish milling. CoroMill Plura with 50 degree helix in grade GC1620 is optimized for this application. 7
Fan Casing The machinability of titanium is low, however, unlike the nickel alloys, ceramic cannot be applied. This puts challenges on productively removing material. Keeping the cutting temperature low is the key to success. The key factors together, with optimized programming, are choice of insert shape and utilisation of high-pressure coolant (HPC). CoroTurn SL70 the flexible modular tooling system Round inserts offer best accessibility and productivity due to reduced entry angle and chip thickness. The programme consists of round carbide inserts as well as the stable CoroCut grooving system and comes with HPC as standard. High-pressure coolant! Radial and axial clearance requirements covered in compact program Oval coupling offers excellent stability and accessibility Coromant Capto size C6 for multi-task and VTL requirements RCMT 1204MO-SM H13A Trochoidal Cutting speed v c m/min 50 Depth of cut a p mm 3 feed rate (G1) f n mm/rev 0.4 feed rate (G2) f n mm/rev 0.2 Metal removal rate Q cm 3 /min 60 8 Together with the optimized geometry for machining titanium, tailored programming and high pressure coolant the results are high metal removal, security in machining and long tool life.
Vertical Turning Lathes (VTLs), Coromant Capto and Jetbreak VTLs by design need to have either manual quick change or automatic tool change. With the coolant piped through the ram directly to the spindle there are no coolant pressure restrictions - as is the case with turret lathes and rotating spindles. Coromant Capto Jetbreak, developed for UHPC applications in VTLs, has been applied for many years, predominantly in titanium casing, disc and spool applications. Much of the design and application knowledge developed in this fi eld lay behind the now standard CoroTurn HP program for HPC *. High-pressure coolant! Xcel in titanium A radical tooling solution for semi-rough turning into shoulders. Xcel combines the advantages from square 45 degree lead approach angle and rhomboid 90 degree lead angle tools. Rhomboid - accessibility into confi ned spaces and machine in two directions with easy tool offset Square high feed rate and long tool life CNMG 120408 H13A CNMX 1204A2 SM H13A Cutting speed v c m(min 40 50 Depth of cut a p mm 3 3 Feed rate f n mm/rev 0.25 0.4 Metal removal rate Q cm 3 /min 30 60 Tool life min 10 20 Xcel reduces the lead angle and chip thickness allowing an increase in feed and speed Double the metal removal rate and at the same time double the tool life! * Coromant Capto Jetbreak - UHPC - Ultra High Pressure Coolant - between 100 to 500bars (1400 to 7000psi) Coromant Capto HP - HPC - High Pressure Coolant - up to 100bars (1400psi) 9
Spool The two challenging features of this component are the deep internal chambers and the external blade tulip grooves. A combination of engineered solutions and methodology with optimised grades are the key to success. Dampened blades with Coromant Capto To machine the deep internal chambers typically up to 150mm, long, slender tools are required. The challenges are tendency to vibration as well as removal of the chips from the groove. Turning one of the most challenging features into a secure process has been achieved by: Oval serration blade system for best stability and accessibility. The 100mm high blade allows for best coolant delivery to assist in chip removal For blades longer than 4x width of the blade a patented dampening device is part of the design. This allows depth of cut to be 4 times greater than without dampening Trochoidal turning technique combined with ceramic grade CC6060 reduces the number of machining passes required A secure process with more than double the productivity. Without dampening Same cutting conditions with dampening 10
Blade groove on spool Inserts to fi t every groove shape. To complement the standard CoroCut 90 degree programme, blanks are available in 90,45 degree and T-shape for more special requirements. Ceramic grade CC6060 - an optimizer for increased productivity Excellent resistance to notch wear allowing for higher depths of cut to be taken compared to other ceramics Long lengths of cut Profi ling and pocketing using trochoidal turning RCMX turning inserts for finishing Carbide RCMX insert fi ts in same insert pocket as ceramic, reducing number of tools required and set up time The geometry provides low cutting force and good chip control S05F for HRSA or H13A for titanium 11
Shaft Made from high alloy steel or Inconel the major challenge here is the length and internal features of the component. The biggest development in shaft manufacturing has come from the evolution of the multi-task machine. Coromant Capto and Silent Tools are proven to be the perfect partners for shaft manufacture with multi-task machines. High-pressure coolant! Dampened boring bars A standard Silent Tool boring bar programme up to 250mm diameter and 14 x dia to length capability is available. This range of tools can produce component features of an extraordinarily high standard. The serration lock (SL) coupling is now equipped with a full range of cutting heads with HPC capability. CoroCut SL70 the flexible modular tooling system SL70 modular blade system offers easy access into the fl ange around the shaft with high pressure nozzles as standard. The rigid CoroCut system is often used with the TF or TM turning/ grooving geometries for high alloy steels. High-pressure coolant! 12
Coromant Capto/multi-task machining An open system optimized for turning, milling and drilling. Turning tools designed to work with the machine tool s B-axis locked at 45 degrees Tools with multi-functions to reduce the amount of tools required and maximize magazine space Longer tools to give accessibility to centre without the need for adaptors Standard programme of turning tool heads with CoroTurn HP High-pressure coolant! Scallop milling For scallop milling please refer to page 5. Hole making in aero engine shaft For hole making please refer to page 15. Internal bottle boring Certain shaft designs have a bottle bore feature, which is a very specialised operation. We offer pull boring solutions for new component or machine installation projects. 13
Blisk/Impellor Blisks are becoming more common in the high-pressure compressor area of the engine due to the advantages of weight, effi ciency and servicing. The impellor is found in the APU. The machining of the turbo foils is a similar process for both components. Key factors to success are: 5 axes machine with good simultaneous dynamics Turbo 5 axes CAM software Optimized tools and process knowledge for titanium/hrsa Roughing slot- titanium The best method here is point milling. Because we are full slot milling the axial depth of cut is limited to half the diameter of the tool. The CoroMill 316 bull nose exchangeable insert offers a great balance of productivity and economy. Roughing slot- Inconel Applying trochoidal milling with high speed machining techniques is the best method. Trochoidal milling 2D roughing/high material removal method using HSM techniques in a confi ned space or slot tool is programmed with a roll entry and exit from cut controlling the arc of engagement low cutting forces allowing high depths of cut Plura 50 degree relieved shank, bull nose design, is optimized for axial depth of cut twice the diameter and low radial cuts. 14
Finishing the blade profile Flank milling (high axial depth of cut) is the fastest option where the component, the CAM software and the tool allow. The standard programme of conical ball nose end mills is specifi cally designed for this operation. They offer excellent stability combined with reach. The complete modern hole making solution Drill with CoroDrill 846 The latest development in solid carbide drill technology with geometry optimized for HRSA offers a high number of drilled holes with security and low axial cutting forces. Finish bore with Plura end mill Circular interpolation is a fast and secure method, one tool can fi nish a wide range of hole diameters reducing tool inventory. Chamfer with Coromant Capto CoroTurn XS This tool replaces infl exible special tools and can even be used for all de-burring and not just holes. 15
Fan Disc Made from titanium this component has internal chambers to be bored and large tulip grooves to be milled. Dampened blades To machine the deep internal chambers typically up to 150mm, long, slender tools are required. The challenges are tendency to vibration and removal of the chips from the groove. Turning one of the most challenging features into a secure process is achieved by: The most productive and secure method for roughing is with direct grooving. To remove the chips from the chamber without jamming the WCMX GM insert splits the chip into three separate segments Blades longer than 4x width of the blade are designed with a patented dampening device. This allows depth of cut to be 4 times greater than without dampening. Oval serration blade system for best stability and accessibility. The 100mm high blade allows for best coolant delivery to assist in chip removal Once the bulk of material has been removed the round carbide insert together with HPC profi le turns to fi nished shape with dedicated geometry SM High-pressure coolant! 16
CoroCut angled inserts Perfectly formed for those diffi cult to access grooves, 90 degree angled inserts come in a variety of shapes all as standard. No need for special tools. Blanks even available for dedicated 90, 45 degree and T-profi les. Tulip slot milling This feature has traditionally been broached but with new technology this has been replaced with milling. Due to the special form of the groove, engineered solutions have been developed. Rough groove and pre-form opening using side and face cutter Semi-fi nish and fi nish using profi le end mill 17
Surface integrity The cutting process can affect the integrity of the fi nal component that can ultimately lead to part distortion on thin parts or reduced fatigue life in critical rotating parts (discs and shafts). The combination of cutting force and elevated temperatures generated during machining leads to alterations of the microstructure, which can cause changes in micro hardness, plastic deformation of the grain boundaries and residual stresses in the component sub-surface. Sandvik Coromant leads R&D with the AMRC (Advanced Manufacturing Research Centre) to develop optimized grades, geometries and cutting parameters to leave the component in the optimum condition. It has been found that the key factors that affect the severity of the surface change are: 1) Cutting parameters. There is little effect with change of feed, however, increase in cutting speed has a detrimental effect on the surface characteristic with a worn edge in HRSA materials. 2) Grade/geometry effect on insert wear. The critical point is the trailing edge of the insert. This is the part of the edge which transmits heat into the component and generates the fi nished diameter. Wear at this point increases the temperature and forces, resulting in more spring passes and component defl ection. Best surface results have been found with HRSA - CoroCut RO in CVD coated S05F at 50m/min Titanium - CoroCut RO in uncoated H13A up to 120m/min Predictive machining To be able to ensure that the chosen insert style and grade can make one pass, we provide spiral cutting length (SCL) information. For a given diameter and length of cut the SCL can be calculated for a given feed rate the correct speed can then be applied to guarantee making the pass with accept able wear, giving good surface integrity and dimension, preventing any need to re-cut. Best practice for finishing Roughing - if using ceramic, stop within 1mm due to high material deformation Finish with carbide 3 passes use SCL to ensure cutting data gives cutting length required carbide ceramic roughing semi-fi nish fi nish/measure a p 2-3 a p 0.5 a p 0.25 measure 1) semi fi nish - 0.5mm 2) fi nish measure same insert style and geometry as fi nish cut - 0.25mm 2b) measure component to gauge last cut, size to correct offset of tools 3) fi nish cut to size fi nish to size a p 0.2-0.3 fi nished comp 18
Total component solutions Turbine Disc Turbine Casing Fan Casing Spool Shaft Blisk/Impellor Fan Disc For more information please check our catalogue supplement or visit www.aero-knowledge.com Coromant Capto, CoroMill, CoroCut, CoroTurn, CoroDrill and GC are all registered trademarks of Sandvik Coromant. Head offi ce: AB Sandvik Coromant SE-811 81 Sandviken, Sweden www.coromant.sandvik.com E-mail: info.coromant@sandvik.com C-2940:123 ENG/01 Printed on recycleable paper. Printed in Sweden, AB Sandvikens Tryckeri. AB Sandvik Coromant 2009.01